I dismantled my other box just to see what all it is comprised of:



I don't know if they went to a different design after '93; but this one had no thrust washer. Just a rubberized plastic tapered bushing that fits onto the tapered surface at the superior end of the shaft. The rest of the shaft was machined polished; but had no bearings/bushings/washers/etc. Also, on the inside of the case there is just one small grease passage about 1" long at each end. Doesn't do much for grease flow; but I guess on a 'non-serviceable' part that isn't a major concern once the initial charge of grease is pumped in.

This spare idler was just starting to pit where the spring contacts the top of the shaft. I didn't get a good look at the top of the shaft on the one I rebuilt since I just cut the very end off; but I suspect more extreme concaving was to blame for the laxity moreso than the spring losing tension. A hardened washer between the spring and the shaft with grease grease channels ground into it would be a good idea, IMHO.

I may go ahead and redo this one with the threaded pipe idea mentioned above 'just to do it'. Updates if/when that happens. <img src="/forums/images/graemlins/kewl.gif" alt="" />

[edit]BTW, if someone did have access to a lathe, I think it would be pretty easy to machine down the taper to an appropriate parallel surface that matches the ID of a roller bearing with an OD that is a snug fit to the ID of the case. <img src="/forums/images/graemlins/cyclops.gif" alt="" />