Topic: T-case hell

[TATER]

  After doing the dual cases, I'm having trouble getting anything out of the rear output.  While on jackstands, everything seems fine. Front output turns in 4-lo or hi. Rear output turns in 2h, 4h and 4lo. I do not have a front d-shaft on at this time. Set the truck on the ground and I get nothing out of the rear. Not in 2H,4H or 4Lo. The front output turns in 4x4, in 2H it can be stopped by hand. I have let out the clutch while shifting the T-case shifters and get a grinding until clutch is pushed in enough to engage the gears. With the t-cases engaged, engine dead, Up on a jack,  I cant turn the wheels. Yet when I lower the truck, start the engine, I get nothing exept the front. The rear has worked twice so far only to make a thud noise and the nothing but the front.

   Yes, the back case shift rail was cut. Yes, the front case shifter detent ball in in. The shifter itself doesn't "pop" out of gear. The shifters work fine. No binding. Before using jackstands, I had the same problem and was under the truck ( while it was running ) grabbing the front output and the rear engaged,jumped about a foot and died. Luckily I wasnt run over.

[79coyotefrg]

hence you would be called Mashed Tater    
sounds like the gears are NOT meshing in the rear case,  did you prepare the crawler or did the guys at marlin?? 

[TATER [OP]]

  I did it myself. It worked wonderfully on the bench before install. The rear case was bought at a junkyard. I took my time, used the crawler installer instructions.

  If the gears arent meshing properly, how can they be fixed?

[UNBREAKABLE]

Did you put the dowel pin back in the shift collar?  Have you checked the shafts(input/output) to see if they are broke?

Thats pretty good 'bout the "mashed tater" 

[TATER [OP]]

  Pin is in the shift collar. I can let the clutch out slowly and feel  the collars engaging.







  And I haveheard every TATER joke out there.

[derek]

is there enough clearence around the shifters to allow them to shift all the way into 2wd.
it may be hitting the body and bumping it into neutral.

derek

[TATER [OP]]

No body lift to interfere w/ shifters.

  This thing has me stumped. I suppose its gotta come out and get the once over.

[FIREBALL]

Did you say theres no front shaft yet? Is ist still up on jack stands?
If so get the shafts in, and get it on the ground and try it. They will do some strange things while in the air. Just the friction of the gear oil will make things move that you don't expect to. If it worked on the bench, there's not much reason that is shouldn't in the truck.

[TATER [OP]]

It was on jackstands when cases were installed. No longer on stands.

  Right now I cant get it to move at all.

[79coyotefrg]

yea Tater,  better pull your case and take it to that guy you said would fix for cheap,  or ship it to Marlin,  that would probably be best,   or go back thru the install instructions real careful and see if maybe you missed something

[BigMike]

Look, if you are getting power to the front output then I completely 100% guarantee no question you MUST get power to the rear output because the output shaft is what powers the front output. So if you are telling me that your rear flange isnt getting any power, then you must have left out
the shift collar ring that goes between the low speed gear and the input gear.

The only way then for the front to turn would be from the frictional forces between the bearings and gear contact, etc, and you would be able to stop it by hand -- and that goes for the rear output as well.

Listen, if your front output is spinning then I GUARANTEE that the rear output is turning at EXACTLY the same speed for they are CONNECTED in 4WD and are one in the same.

The only possible reason for this is that you have a broken output/mainshaft and you have a permanent rear disconnect which is cool, but not cool for driving around town.

Either your mainshaft is broke in two or your definition of the problem is misleading me.

BigMike