Help diagnose my t-case/trans problem *long*

[85RunnerAZ]

Posted on pirate here: http://www.pirate4x4.com/forum/showthread.php?s=&threadid=216196

Ok, I just put in my MC07. My case is an 85EFI and I used a 83 as the donor. The bearings appeared fine in the donor case. I put the stuff together and it worked fine for my test drive...1 mile long. Then later I took it on a 15 mile drive (2hi). While leaving the driveway, it was hard to shift (Trans.). Then in 4-5th gear it would make a noise during decelleration (kinda the same way a bad pinion bearing does during decelleration). ...so I thought it was just bad bearings in the donor case. Then, it kinda chunked - like a ball came out of the bearing and there was significant resistance in the drivetrain. I was close to home so I decided to 2nd gear the rest of the way home since I was pretty sure I knew where the problem was.

Well, After checking it out, here's what I got:
- With the truck in neutral, the motor dies when I let the clutch out. - this would make me think its the input bearing on the transmission, not the t-case.
- With the transmission in neutral, the t-case output shaft won't turn - which kinda negates the trans. input bearing.
- Oil in the t-case had a little bit of metal in it but not very much at all...I've seen oil changes on VW's worse than that.
- Oil in tranny had no metal but only a quart (maybe less) came out. (I topped it off 6 months ago).
- The trans. sat at a 30* angle (output shaft down) for a night - nothing came out of the tranny seal W/OUT the t-case in.
- The output on the t-case turns freely with the t-case in neatral
- The throwout bearing has been making noise for a while...and it is still making the same noise.
- When my clutch gets really really hot it slips - after crawling and feather the clutch ALOT in regular low.

So, all logical guesses tell me it should be the new addition to my drivetrain - the donor case's bearings. However, that shouldn't affect the way the transmission shifts and with the trans. in neutral the motor shouldn't die when I let the clutch out.

Many times when I work on my truck other misc. stuff goes out - like I can change a rearend and suddenly the waterpump goes out...so I am not ruling out the Trans being bad, even though it didn't make any noise prior to the event. I am consdering that by letting the trans sit at a 30* angle for a night while being low on fluid that maybe it all came back in to another chamber and lube was lost...


I will be tearing it apart in a few days...any ideas what it could be?

[85RunnerAZ]

Here's an update:
The wrong input shaft was on the front case (the output shaft with the extra splines), not the rear. It was creating the problem though. The input shaft was applying pressure to the output shaft of the transmission. When that happened, It must have ruined the bearing on the output shaft. I put the new output shaft in and threw the t-case back in. The trans is making alot of noise, but at least it isn't binding anymore! I can't seem to find a good schematic of the trans but I am thinking that I can pull the tailshaft housing off anf replace the bearing. Any suggestions would be helppful.

[Marlin]

Here's an update:
The wrong input shaft was on the front case (the output shaft with the extra splines), not the rear. It was creating the problem though. The input shaft was applying pressure to the output shaft of the transmission. When that happened, It must have ruined the bearing on the output shaft. I put the new output shaft in and threw the t-case back in. The trans is making alot of noise, but at least it isn't binding anymore! I can't seem to find a good schematic of the trans but I am thinking that I can pull the tailshaft housing off anf replace the bearing. Any suggestions would be helppful.

I was hoping that the mainshaft center bearing would live thur the added forward pressure
You would be waisting your time to remove the trans tailshaft housing in the truck.
Not only does the trans need to be pulled out, but the fifth gear assemble needs to be pressed off to gain access to the failed center bearing
I think it is time to call me again to discuss your options.
I sell a maximun bearing for your transmission, but it is not a easy job to install. You are going to need gear pullers, ect., to get this job done.
Give ma a call    Marlin
(559) 252-7295

[85RunnerAZ]

Well Marlin:
  I bought a replacement trans since I didn't have time for a rebuild.....and the used trans sucks!! It pops out of 1st gear and 5th's bearing is shot. SO, I am gonna rebuild my orginal trans (the one we spoke about in the posts above) since it is a low milage unit - rebuilt recently. Here's my question to you: How much will it cost to put a new center bearing in? I have the transmission torn down to the point where it is time to use a puller. (I pulled off the case and I removed the shift rods). I remember that you offered a discount since the directions said to grind off the extra splines on pre83 t-cases if it is used a rear case....and I used mine for a front case. Let me know what you think.

I don't have alot of time to call since I do taxes and it is tax season!! So if you can reply to this thread or email me: [email protected]

[Marlin]

I would be happy to help you out right away!
Please call the shop in the morning, and i will talk to you about sending your trans to me.
I will tell my guys to put you thur.....

Marlin