Topic: dual-cases Q

[mike c]

I am putting together dual-case together, I putt the main output shaft in the plate, my oil clearance is (.010) (.011) will fit but tight. Is that to much? Is there something to fix that? I used new thurts washer and new imput shaft.  

[MiniSimp]

Clearance should be between .004 and .010
If you can get .010 you're good to go.

[mike c [OP]]

Is there anything to make it smaller gap .011 will fit alittle tight

[BigMike]

Are you talking about the clearance between the low speed gear and the coupler that is determined by the thrust washer that sits behind the low speed gear and in front of the main adapter bearing?

If so, then 10 or 11 thousandths is wwaayy to much free play, and I couldnt imagine it being to tight at that spec. It should have 0.004" of free play if that is what you are talking about..

[MiniSimp]

If so, then 10 or 11 thousandths is wwaayy to much free play, and I couldnt imagine it being to tight at that spec. It should have 0.004" of free play if that is what you are talking about..

But how would you fix it?

[BigMike]

Get a thicker thrust washer

[mike c [OP]]

I used the thrust washer that came from marlin. It should be .004-.010 marlin tech info

[busybum]

Are you talking about the clearance between the low speed gear and the coupler that is determined by the thrust washer that sits behind the low speed gear and in front of the main adapter bearing?

If so, then 10 or 11 thousandths is wwaayy to much free play, and I couldnt imagine it being to tight at that spec. It should have 0.004" of free play if that is what you are talking about..

i have .030-.031 clearance between the supplied gear/shaft and the gear it rides against but i don't have any free play.  what does that mean?

[BigMike]

Hey busybum,

First, let me say that when I said "10 or 11 thou is wwaayy too much" I must have fallen off my chair right before posting that. 10 or 11 thou is about the max of what we allow.

In your case, 30 or 31 thou is wwaayy too much clearance between the shift hub teeth of our coupler and the low speed idler gear.

Please consider the following image from our old online instructions.
(note for future reference: this image will be removed from our server soon)


For the time being, you can find this step on our "Old" Crawler Installer found on page 7 in this PDF file:
http://marlincrawler.com/sites/all/marlin/files/docs/crawler-installer.pdf

Could you please verify this is where you are experiencing .030" gap?

Thank you in advance,
BigMike

[busybum]

Hey busybum,

Could you please verify this is where you are experiencing .030" gap?

yup. i had a .030 gap where indicated on your pic but i had .004 tolerance.  if i tapped the gear in i had a .026 and tapped out it was ~.030.  do i need to shim it and if so what do i use?  i have it all together now but it's just setting under the bench until i'm ready to build my rig. i'm ready to take it apart if i need to.  let me know and sorry for the delay on responding
thank you!

[Marlin]

I have never seen 0.030 end play. That is 3 times the allowed amount.

In my years of assembling Marlin Crawlers, the most ever was 0.015 and it was on a early high miles noisy gear set.
What does the machined faces on the sides of your low speed gear look like?
Toyota specs the thrust clearance to be from 0.0039" to 0.0098" with the limit at 0.0118".
I designed the dual cases to have around 0.010" end play to aid in high speed applications.

The factory does not publish the specs for the width of the low range gear. My samples read at 31.92 to 31.94, (1.2565" to 1.2575").

Please make sure that you are using the 0.108" thick retainer ring that we supply in our kit and the supplied thrust washer is 0.293" to 0.295" thick.

Also, I trust you are reading in thousands, not millimeters. Note that 0.012" is .305 mm.

I have heard of my plates that have had excessive endplay, but until now have never seen a pic.

Hope this helps,
Marlin

[BigMike]

--> Marlin

[busybum]

Please make sure that you are using the 0.108" thick retainer ring that we supply in our kit and the supplied thrust washer is 0.293" to 0.295" thick.

it's been awhile since i put it all together but i am going to pull it apart.  it's been setting under my bench and doesn't even have oil in it yet.  oh, and i used the supplied retainer ring and thrust washer, was definitely measuring in thousandths, and the gearcase is out of an 80 hilux with unknown mileage...
Hopefully i can get to it soon and i will definitely take some pictures and post them if i can figure out how to.
Thank you for the response Marlin.

[busybum]

i took the reduction box apart again and i have a .004 tolerance.  i wasn't getting the feeler gauge deep enough and was measuring the tolerance on the gear teeth just above the machined surfaces.  thanks for the advise and sorry for confusion.  You guys make the best products! can't wait for high steer and power steering

[BigMike]