Jon, I sent you an email with an early draft of the gear installation instructions that contains the full parts list. Hmm, is someone going to be making port in Japan soon? <img src="/forums/images/graemlins/kewl.gif" alt="" />

C'mon now, it would be bad OPSEC (my personal operation) to tell you that... <img src="/forums/images/graemlins/lol.gif" alt="" />

Thanks for the email, there's a lot of parts there! You've got a GREAT start on some very comprehensive intructions, BTW! <img src="/forums/images/graemlins/kewl.gif" alt="" />

http://www.drivetrain.com/transfercasesparts.html#MITSUBISHI

This MIGHT help you out... I stumbled across it earlier this morning while looking for NP241 rebuild kits.

DD, if you have any part numbers or specs, PM them to me and I'll see if there is anything available aftermarket.

Hazy, PM sent.

I got it apart mostly. Having a really hard time with the snap ring that holds in the input gear. I must have spent 3 hours just trying to get that one snap ring off--it keeps slipping off my snap ring pliers. The snap ring is really stout. Seems like I need a better set of pliers.

Replied <img src="/forums/images/graemlins/kewl.gif" alt="" />

Sometimes it feels better making due than getting the right tool.

I got the input gear snap ring off by modifying the tips of the tool. I ground off the little dinky tips till I got to the thick shaft of the tip, and then filed in a groove that tapers in--thinking that this would make the snap ring lodge in the groove rather than slide off. Worked like a charm.



My original input gear does not appear to have the backlash eliminator feature that some trucks had. The Aussie gears come with a new one, just in case. That's it hanging on the shaft of the new input gear on the left. Original on the right. Maybe I'll make it into some bling. <img src="/forums/images/graemlins/lol.gif" alt="" />

My input gear woes continue.

I almost missed something. There was a seal cap installed in the center shaft of the input gear. Luckily I noticed and removed it and reinstalled it in the new gear. If I'm not mistaken, I would have leaked a lot of oil out the splines where the transfer case connects to the transmission adapter.



But this sucks! The bearing stop on the new input gear goes too far up. Even with the bearing installed and the thickest possible snap ring in the groove, there's still about a millimeter gap between the bearing and the ridge where the bearing is supposed to rest. New one on the left.



Here you can see the gap better.



In fact, the gap is a bit larger than that, because there's a slight gap between the bearing and the snap ring. The bearing is installed too far.



I guess I have to get a machine shop to make a spacer. Project on hold for awhile.

Not necessarily a bad thing, because it may take some time to remove that armored gasket sealer Mitsu used on the chain cover. <img src="/forums/images/graemlins/scared.gif" alt="" />

After I measured the gap, hmmm, it was just about the same as one of the selectable snap rings that goes in the groove in front of the bearing. So I picked the smallest one, 2.30mm, and fitted it as a spacer. There's no groove there, but it expanded out flat.

The snap ring in the groove in front is nice and tight too.