mudmaster's 83

[:)bestgen4runner]

Took on the challenge of fixing Mud Masters "Marlin Crawler built" 4.7 transfer case.
Here is the cross threaded nut that I had to cut off using an air hammer.
I am not going to bash or point fingers in any way. I'm just going to state facts and show You what I found.
Maybe someday this will help somebody out.
Hogcanyonhopper 

[:)bestgen4runner]

You can see the damages caused by limit clip never being installed.
The 4th picture shows the clip installed correctly on a different transfer case.
The clips is there to limit the forward movement of the lower shaft and bearing.
Without the clip in place it allowed the bearing and large 4.7 gear to move forward and contact the case.
You can see from the picture the large circular grind marks in the case. these are not part of the clearencing process for the 4.7 gears. You can also see around the outside of the pocket bearing where the opposite side of the large 4.7 gear, the shaft side was contacting. I suspect this is due to the large gear kicking back in the case when it would contact the forward case. Mud Master had also pointed out to me that He had heard a bump bump type of noise. I believe this noise was caused by the large 4.7 gear bouncing forward and back.

[:)bestgen4runner]

Here are a few pictures of the cleaning and reassembly  process. Mud Master had Me install a RCV rear output shaft.  Very nice piece.
Note, The RCV upgrade output shaft has no oiling holes. This was strange
I placed a call to RCV and they said that is how they make them and that there is no issue.
Good enough for me.

[:)bestgen4runner]

So after diagnosing what went wrong with the original build, cutting off the cross threaded nut, replacing the missing clip, cleaning out all the metal shavings, installing a new upgraded output shaft, and
replaced all the gaskets.
Mud Master Again has a "Marlin Crawler 4.7 transfer case" this time built by BestGen.   

[:)bestgen4runner]

I almost forgot to post pictures of all the metal I found inside. 

[mudmaster]

Thanks for the rebuild Bestgen!

[mudmaster]

Got my cup holders installed last night.

[oleblue22]

Nice! Where did you find those?

[mudmaster]

I've had them too long to remember, but it looks like Desert Rat has them:

http://www.desertrat.com/products/?id=4105

[mudmaster]

Elbe 3/25/17

[mudmaster]

A little scenery

[mudmaster]

Found a deep hole

[mudmaster]

Some flex

[Rockcrawlintoy]

[mudmaster]

Thanks for the pics

[mudmaster]

Got the hydro assist installed finally. Old junkyard sourced box is out.

[mudmaster]

New  (PSC) and old.

[mudmaster]

New (PSC) box installed.

[mudmaster]

Top view.

[mudmaster]

Bleeding.......

[mudmaster]

Done and no leaks.

[mudmaster]

So since I bought this truck it hasn't had a proper ignition switch on the column. I decided it was time to fix that issue. Finding a new steering lock mechanism proved to be impossible as mine was bent and cracked where the switch wiring resides. I found a used one with a key at a local junkyard and ordered a new ignition starter switch on ebay. 

[mudmaster]

Everything is off here

[mudmaster]

Old steering lock mechanism .

[mudmaster]

New to me one with new ignition starter switch. Still haven't got it all installed yet........

[mudmaster]

Getting it back together.

[mudmaster]

Getting closer

[mudmaster]

Just about there.

[mudmaster]

All done and it works!

[Willard]

What ram and hose kit did you use? I also have the PSC box and they placed the port on the front the same on my box and it is going to be a PITA to hole saw through my body mount to run a hose to it because my box is so far forward. Are you planning on plating your frame for the box or am I not seeing it if it is already there? Nice job BTW.


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