I've checked a number of sources now for clearance specs for rear output shaft for the transfere case, none found.
How much play are with talking about? (1/4,1/8 inch?)
No, I'm talking about end clearance between the bearing and the tailshaft cover. As it now sits with the new rear cover, I have negative .002" (including the gasket) - which means when puled up tight is deforming either the aluminum cover or the bearing cage. Several different spacers are available from MMC, so I've ordered a 1.02mm spacer that should give me positive .002" end clearance, which seems ok to me.... the next spacer would result in .006", which seemed a bit too much, but without an OE standard I'm shooting in the dark. You have to see how it's set up to understand what I'm asking and it's hard to explain (for me)... the shaft assembly is kept from moving forward by a snap ring on the rear bearing of the output shaft... it's kept from moving to the rear by the tail cover - so the bearing is sandwiched between the two limiters. With too little end clearance, it's possible that the snap ring deforms enough to keep the bearing cage from distorting, but I'm not certain - seems better to have just a little clearance.
You're going really quite hardcore with this gearbox Frank, carry on at this rate and you'll be above factory QA specs.
When I tear something down, my goal on reassembly is AT LEAST factory QA standard.... My inexperience probably causes me to overlook some things, but I enjoy tinkering and poking around to see how things work.
As for the lone post, it was an interesting read, just coz no-one immediatly ran to your aid doesn't mean it's a bad post.
What I said about t-case work being for loners was intended to reflect the lack of trouble with these cases - trouble that would necessitate many others having torn them down. By contrast, nearly everyone knows how to replace a starter. <img src="/forums/images/graemlins/lol.gif" alt="" />
Frank
