Hurts Taking One Like This

[OR VietVet]

That bearing and bushing are needed and that bearing is really bad sounding. When you are pulling the chain tight, is that full pull the exact position where the chain would be held by both gears? Glad you are doing the chain anyway. Good luck.

 

[YukonRog]

That bearing and bushing are needed and that bearing is really bad sounding. When you are pulling the chain tight, is that full pull the exact position where the chain would be held by both gears? Glad you are doing the chain anyway. Good luck.

Well it's pretty hard to measure and pretend you know where the correct distance is from the mainshaft to that inner bearing is. So I may be short or long. When I pull it over there's not much play in the chain but to be honest I don't know how much it's supposed to have. So the new case is supposed to have that inner bearing installed and I bought a Borg Warner OE chain. So good or bad, they're getting replaced. Now I'm reading about having to use a special clutch spacing tool from Kent Moore (J 44295) that costs a fortune. I can't afford one of those. Don't think anyone rents them either. YouTuber RickaFix put his together without using one. What do you know?

 

[Mudsport96]

That clicking from 1:50 on sounds bad. I wouldn't think that id normal as that would eventually cause impact wear.

 

[YukonRog]

That clicking from 1:50 on sounds bad. I wouldn't think that id normal as that would eventually cause impact wear.

I plan on pulling it all apart today. Maybe I'll see something obvious. With my luck it'll probably be the planetary gear. Expensive. What concerns me most right now is getting someone to set the correct spacer height on the clutch pack. You wouldn't happen to have the Kent Moore J 44295 Tool you could loan or rent me would you?

 

[Mudsport96]

I plan on pulling it all apart today. Maybe I'll see something obvious. With my luck it'll probably be the planetary gear. Expensive. What concerns me most right now is getting someone to set the correct spacer height on the clutch pack. You wouldn't happen to have the Kent Moore J 44295 Tool you could loan or rent me would you?

Uhh no. While i havent done this particular transfer case, ive done plenty of rear diffs and transmissions without the "j" tools they recommend

 

[YukonRog]

Uhh no. While i havent done this particular transfer case, ive done plenty of rear diffs and transmissions without the "j" tools they recommend

Just concerned about the proper stack height and shim. If I'm putting new clutch frictions and steels in I have no idea how to measure without that "special" tool. Local shop says $110 to assemble for me. Keeps getting deeper.

 

[YukonRog]

Okay, so I pulled it all apart and found nothing like I was expecting. No broken pieces, chunks of metal, rocks or even wear marks. I'm at a loss. I did speak with "the builder" at a local Monroe Transmission store and he said he never bothers with using Kent Moore tool J-44295. He just uses the "feel" method. Assemble the clutch pack and if it has slight play it's good. Hmmnnn okay....says he knows what he's doing.
So made some notes and a video. It apparently takes a while to upload videos so I'll post that when it's done. Meanwhile, I'd like some input and help.

Findings:

1. Inner Needle Bearing in back case noisy and matching bushing on shaft marked up.
2. Missing plastic Vent Valve
3. Discolored Clutch Steels
4. "Slight" play @ front output shaft bearing.
5. Pump starting to mark up inside of back case.
6. "Slight" wear marks on bearing surfaces on mainshaft.
7. "Slight" movement on mainshaft output bearing.

Possibility of Noise: ?

1. Pump "Knock"? Worn pump?
2. Stretched Chain? No marks anywhere.
3. Clutch? Worn discs make noise? Noise didn't seem to come from that end.

Calling all builders.

 

[YukonRog]

Here's the video...

 

[Fjs0001]

The rock sound coming from your truck reminds me of when the throw out bearing goes bad in my old Jeep. It makes me think there might be something wrong with this piece.

 

[Mudsport96]

While its disassembled, stack together everything that is splined, like it would be if the case was assembled. Then, check for slack in spline mating surfaces, and the planetary set. I am kinda grasping for straws here, but without a unit in front of me its hard to visualize.
Edit
Also, check the parts that slide for the high - low range change. Maybe something is out of spec there..