Re: Transfer Case is Out
 

I figure I'll just keep posting progress here..

Solved the worn out tire problem. First since they are 16.5" wheels, no one seems to make decent tires for them any more. Found a set of 16" wheels and tires for less than a set of tires for the 16.5's..

Also got the new variable ratio steering box, rag joint, power steering hoses installed. Front diff is sealed up and ready for gear oil. Broken windshield is out and a new one is ready to go in. One broken motor mount replaced with the other going in today. Transfer case teardown will start tomorrow I think.

Re: Transfer Case is Out
 

You can use a Jeep XJ steering shaft to do away with the rag joint and tighten up the steering.They are very simillair to the high dollar Borgeson unit's.
http://i59.photobucket.com/albums/g3...le/pics580.jpg
http://i59.photobucket.com/albums/g3...le/pics582.jpg

Re: Transfer Case is Out
 

Not sure what an XJ is. Guess I need to do some searching once the rag joint starts getting soft in a few years.


On a positive note, got the transfer case torn apart today. Now to clean it all up and hope the parts kit arrives tomorrow. Any good sources for the output yoke retaining nuts? One of the came off about half stripped. Threads on the shaft aren't too bad, should be able to clean them up with a thread file.

Re: Transfer Case is Out
 

I'll have a few.Front or rear out-put??

Re: Transfer Case is Out
 

Nice truck...where did you get the steering box at?

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Steering box is a new AGR variable ratio box 13/16 to one. It's about 3 3/4 turns lock to lock. I've yet to drive it so I can't go beyond the install which is simple except for the one arm bench press of the box while trying to get the bolts in it. Fits just like the stock box but doesn't have all that slop..

Re: Transfer Case is Out
 

was it about $350? thanks..

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Close, just a little more at Summit.

Re: Transfer Case is Out
 

Finally made some progress on putting things together.

Transfer case is starting to go together.

1 Nice kit
2 Neat trick to install bearing races. Cool them on dry ice and they drop right in - no hammer or press required.......
3 New race dropped right in.
4 Dial indicator setup to check the end play of the idler gear on the new bearings,

Re: Transfer Case is Out
 

Thanks for the tip on the ice, keep forgeting that. Nice work, t/c looks good in that grey color. How'd you make out on the yoke nut? J.

Re: Transfer Case is Out
 

1-tonmudder took care of me on that.

Forgot lat night.. but I had to make a couple of shims to get the clearance set right on the new bearings. Good thing I had some 0.05" shim stock. Just took some patience with some aviation snips and a Dremel tool.

Got the hardware ready to twin stick it as well..

Re: Transfer Case is Out
 

Made some progress through the week and a couple of hours yesterday. Hopefully I can get it back in today.

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And a couple more..

Re: Transfer Case is Out
 

That my friend is a work of art, you'll have to mount a mirror to show it off:lol: Good work, matches the rest of your truck

Why the burrs on that one gear, is that from shifting in and out? Just curious, never had one apart

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My thought at first. If you'll notice, all of the teeth have the same 'burrs'. My take is that it is actually a relic of the way the teeth were made on the shaft - punched from one side versus ground. Which makes sense since it would be cheaper and faster to make them that way. The faces of the teeth look fine so I think I'm ok with them as-is.

Don't worry, the rest of the truck is not near as nice. The pictures hide so much:lol:

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Was making great progress cleaning and painting the last of the parts. Got most of it together until I figured out I need some different seals for the TC to trans adapter. Oh well. Did check fit the twin stick shifter. While it's a pretty nice piece, there are some details that I'm not to fond of and will likely change. Bolts too long an some of the pivot points have no way to maintain clearance between parts. Need to add some bushings and then bolts to retain the parts.

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Where Did You Get The Dual Stick Conversion. Thanks Daren

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Kit is from www.offroaddesign.com. Go the new modified shift rails to go with it so I can have the full functionality of the twin stick - Hi & Lo 2wd rear, Hi & Lo 2wd front, and Hi & Lo 4wd. It also can with a cool boot for the 2 sticks. I'll post the install as I go.

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Everything Looks Real Good, Thanks Daren

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So how did things turn out? I'm going to be dropping my TCs soon and had a few questions....

Looks like the bearing and seal kit you used is the same one I'm ordering (transmissionpartsplus off of ebay) and I noticed you mentioned you needed additional seals for the TC to adapter. From what I've read here on the forums it should be part #3968050. Is this correct? How many, 1 or 2?

In regards to the shims for the clearance on the bearings... are these something I may need?

Anything else I may need?

Thanks

Re: Transfer Case is Out
 

Turned out just fine. Drives every day now.

That's the kit.

Seals, I forget the P/N but I found it on the forum here and got them at NAPA. You will need two of them. Take some pictures as you take it apart and save your old parts until you've matched them up (especially for the adapter seals - so you know you have the right ones..). Installing the adapter seals is a little tricky because they go in backwards at each end (the flat side goes in first). If you can make a driver for them great, if not, improvise.

Shims, yes you might with the new bearings. Be ready to assemble and disassembly the idler shaft a few times to get the clearance right.

Other needs - lots of cleaner for parts and case. Be sure to use thread sealer or locktite on the bolts when you put it together since most of the holes are through holes and will leak (small but annoying) if you do not seal them. Dial indicator to check the end play of the idler shaft. A strong friend to help lift the assembled case. Some grease to help hold the new needle bearings in place while you assemble the gears. Long drifts or punches to drive out bearing races (races in the idler were tough since there wasn't much edge to get the punch onto). One more item is a new seal from the adapter to the trans. Not sure what you have, mine's a TH350 so there was an o-ring I needed but it has a square cross section instead of the typically expected round cross section. Chevy dealer has them. They just gave it to me, cool, your results may vary.

I see you're in CA. I'm in northern OC and can help if you're nearby..

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Great write up, thanks.

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Pulling up an old one here. What ever happened with the doubler and NP205 build?