Topic: T-case rebuild? (bearing failure)

[PhantomD aka Zach]

I had a bearing failure in my dual case adaptor
http://board.marlincrawler.com/index.php?topic=43852.0
 which introduced a large quantity of fine metal shavings to the oil. The rest of the bearings seem fine but the bearing surfaces (where the balls run) is not shiny and smooth like I would assume they should be.

1. Are the bearing races supposed to be shiny?

2. can I get away with using a "minor" rebuild kit (inchworm gear) since the needle bearings should be fine.

3. Run it as it is, but replace the front output bearing (it is lowest in the case and had the dirtiest oil)

4. Do I need a press to install any of the bearings?

Suggestions? Comments? Experiences?

-Zach

[santa cruz crawler]

I would put all the inch worm rebuild stuff in and or , marlin rebuild stuff or see who has a box of stuff from rebuilding dule case.  Mabe cheaper but
Once you get that case apart you will see , it's real easy and open marlins page for the 4.7 and go along with it.    Good luck. Ask for questions if you need to
I'll check you out soon

[PhantomD aka Zach [OP]]

I totally forgot I have a box of case parts, I will have to dig into those and see if the bearings are any good. Then I can compare the races and make a judgement on my current bearings.

Thanks for reminding me.

-Zach

[santa cruz crawler]

Any luck?

[PhantomD aka Zach [OP]]

I had one bearing in the box, I ordered a rebuild from TG and boy was that a mistake! it was not as advertised, I will just leave it at that...

had to send it back and ordered a kit from inchworm, which was a much nicer kit overall and they updated the online picture for me as well.

I have not had a chance to install it yet, but I got more bearings and higher quality gaskets for slightly more.

I should be good to go once I get a chance to install it.

-Zach

[santa cruz crawler]

Trail fear!!!     Inchworm is great stuff , cool good to here !!

[PhantomD aka Zach [OP]]

Finally got a day off and worked on the truck, got the transfer case completely disassembled and cleaned (spotless  )

so now I am ready to get the old bearings off, I guess just a gear puller? so I need a press and a bearing separator?
-Zach

[PhantomD aka Zach [OP]]

Started putting the cases together and I am missing a bunch of snap rings, looks like the common problem of forgetting the snap rings for the pressed on bearings has happened. I have a box of case parts and I hope they are on the old gears still! otherwise I might be in need of new snap rings


EDIT#2 this is cross posted on gen4x4 but i figured its decent tech stuff so I modified this post as to not BUMP the thread to the top
http://board.marlincrawler.com/index.php?topic=78311.0


EDIT: THIS POST HAS BEEN EDITED MANY TIMES

here are the ones I need, I do have a small one that is in good shape, which I thought went on the main shaft in addition the the large one near the big bearing, but looks like it goes elsewhere.

I put this up more for my own reference then anything since it looks like I have to visit a junk yard or dealer to get the parts.

so for future reference (as long as the pictures stay up) these are all the "tool breaking snap rings" aka PAIN IN THE ASS snap rings in the case, the rest are just easy bearing snap rings which you can pretty much get out with your hands.

Input gear 1.280"x0.084" snap ring (thick snap ring)

Toyota Part# 90520-33168 ~$7.50  



Countershaft bearing1.177"x0.084" (Thick snap ring)
Toyota Part #90520-30215  ~$4.50



Main Shaft (the large one) (no measurements)
Toyota Part#90520-36252 ~$9.71 



Idler gear (located on the shaft NOT the bearing) 1.090"x0.060" (thin snap ring)
Toyota Part# 90520-28243  ~$4.40



EDIT: I noticed that the three smaller snap rings rode on different size shafts, I found one left over from an old 2.28 spur gear and I had one left from my build, one was thinner then the other and was clear which shaft it fit. I was unable to measure the main shaft snap ring slot as I could not fit my caliper inside the partially assembled case.

I will try and order them from the dealer tomorrow, I will report back what I find.

OH, the FSM states you must find a size of snap ring that fits best when doing this, they list 4-5 thicknesses for each


-Zach

[santa cruz crawler]

Wow.  Lots of info rite there !

[PhantomD aka Zach [OP]]

got an e-mail about this thread being having a new reply. I realized I never responded after going to the dealer so here's what happened...

The dealer does indeed list many snap rings, each had to be ordered.

I got one that was slightly too thick for the main shaft and had to pretty much force it on (not enough to visibly deform anything, but it took some force) the rest just dropped in. case has been solid for the past 7 months or so, I dont drive it much, but it feels good doing it the right way...