I decided to go for the full rebuild while installing the gears. I don't know the history of the spare case, plus I want to protect the investment in the gears.

Got a few questions.

1. How do I relieve the staked lock nut on the rear output drive shaft?

2. How do I stake the lock nut back on?

3. Should I get a new lock nut, or is it OK to restake the original?

4. Regarding rear output shaft reassembly, the FSM says to apply transmission oil to rotating and sliding parts prior to reassembly. Surely they mean transfer (gear) oil?

5. What is an equivalent to 3M ART part number 8660? This is used to seal the transfer case gaskets. I assume any gasket sealer would be OK. Should a substitute be the hardening or non-hardening variety?

6. What is an equivalent to 3M stud locking 4170? This is used on the cover bolts. Red or blue threadlocker? I'd sure like to use blue in case I have to take it apart again.

The following questions probably require guidance from someone who has actually rebuilt one of these transfer cases.

7. The FSM (1989 FSM page 21-161) has the following instructions. "(22) Measure protrusion A of the front output shaft rear bearing and recess B of the cover and calculate the clearance. If it is more than nominal, place a spacer at illustrated location. Standard value: 2 mm (0.078 in.)" I assume the intent is to prevent bearing lateral movement by having the recess support the bearing. So if the bearing protrudes, say, 4mm and the cover recess is 4mm then I don't need to install a spacer because the protrusion would fill the recess perfectly. But if A is 3.5mm and B is 4mm, then I should install the spacer, which from CAPS, appears to be 0.5 mm. If this is right, what is the "standard value: 2mm" supposed to mean? At first I thought "nominal" was the standard value, so if the difference between B and A was 2mm or greater, then install the spacer. But if the spacer is only 0.5mm, that would give the bearing 1.5mm to move, which sounds like too much. I guess I could measure the protrusion and recess dimensions when I disassemble the transfer case, and determine the intent if a spacer was or wasn't installed by the manufacturer.



8. Also from the same page of the FSM. "(26) Install the wave spring spacer (if necessary) on the rear of the bearing." What conditions make it necessary?

Once I have answers to these questions, I'm ready to place the order for the rebuild parts and start tearing stuff apart!