Transfer Case Problems - Questions

[blackdiamond]

I'm running a Marlin Crawler dual ultimate that has an 85 rear case and an 89 front case.

A few months ago the needle bearing on the countershaft in the front case failed and brought me to a screeching halt.  The front case was rebuilt and this weekend it seemingly had another failure in the front case.  Both times the rear tires ended up locking, on dirt the first time and on wet pavement the second.  The first time the front case got extremely hot, but the 2nd it was warmer than the other drivetrain parts, but I could put my hand on it easily.

Are there any compatability issues with front and rear cases?

Any ideas for what is causing the failure?

[79coyotefrg]

all i can think of  is  installer error  or  bad bearings,   did gotrocks install them ??   im sure  he  knew  what to do  so  i would wonder  if  you had  enough lube in the front case
did you dump a qt  in the front case when you filled them ??

[blackdiamond]

gotrocks and snowrunner (?) did the installed the front case on my Marlin 4.70 case and I had a local shop do the rebuild after the bearing failure.  I changed the fluid via the front shifter until it ran out of the fill hole in the rear case.

I'm hopeful that the failure mechanism is obvious when they get it torn apart. 

[MiniSimp]

Sounds like no grease used on the needle bearings, I'm sure the oil should lube it enough, but I like mine heavily coated.
When I broke down my cases after 3 years there was still grease covering every part.

Have you checked to see if the shaft is true?

[blackdiamond]

The verdict from the shop is that the needle bearing failed again.  They had already talked with Marlin Crawler and the parts were on the way under warranty.  I'm across the country so I don't have any other details.

[gotrocks]

Sounds like no grease used on the needle bearings, I'm sure the oil should lube it enough, but I like mine heavily coated.
When I broke down my cases after 3 years there was still grease covering every part.

Have you checked to see if the shaft is true?

Why would you have grease in your t-case?

[THK Matt]

Why would you have grease in your t-case?

http://www.marlincrawler.com/htm/transfercase/crawler_installer/index.htm

its explained in this

[blackdiamond]

So the question is if not using the grease during install would result in bearing failure? 

[MiniSimp]

So the question is if not using the grease during install would result in bearing failure? 

No idea.
I just grease the hell out of all my parts from habbit.

[blackdiamond]

I called Marlin Crawler about this and was told it would cause premature wear but couldn't say how much it would be expected to shorten the life of the bearing.

I'm sure the shop used grease since it is included on both the Marlin Crawler and Trail Gear assembly instructions online.  I'm not sure which set I printed for them last time, but they have the Trail Gear stuff this time for reference because the pictures are larger.

[79coyotefrg]

Why would you have grease in your t-case?

your supposed to put grease  on them  so they dont fail  when  the first start  running

[blackdiamond]

Since I didn't assemble the dual crawler, does the dual adapter bolt directly on the rear case or is there some dissembly required on the rear case?

[79coyotefrg]

the rear case bolts to the adapter  just like it will the transmission

[blackdiamond]

the rear case bolts to the adapter  just like it will the transmission

So in the standard configuration the gear oil in the transfer case goes up to the rear of the transmission?  This is why the front and rear cases share oil?

[gotrocks]

Yes.

BTW I talked to snowrunner and the original bearings were greased when installed. So I have no idea why the first one failed and even less of an idea why it failed you again.  I hope they find something because I know it was done right on this end.

[BigMike]

Regarding the pre-assembly grease, it is not going to make or break anything. It is not going to cause "Excessive wear" and I certainly would never loose any sleep over it, especially with something so primitive as the gear drive t/case.

Question: What serial # is your dual case adapter please?

Thanks,
BigMike



EDIT: Fixed a grammar mistake

[blackdiamond]

Regarding the pre-assembly grease, it is not going to make or break anything. It is not going to cause "Excessive wear" and I certainly would never loose any sleep over it, especially with someone so primitive as the gear drive t/case.

Question: What serial # is your dual case adapter please?

Thanks,
BigMike

#3455

[gotrocks]

Regarding the pre-assembly grease, it is not going to make or break anything. It is not going to cause "Excessive wear" and I certainly would never loose any sleep over it, especially with someone so primitive as the gear drive t/case.

Thank you for saying this.  I didn't think I was crazy when I wrote my earlier comment about grease.  It just doesn't seem like it would be such a crucial thing to cause a premature failure.

[BigMike]

especially with someone so primitive as the gear drive t/case.

"someone" .... whoops ha ha

BD: I will try to get back at this tomorrow, sorry it is a mad house at the shop with the convention this weekend.

Thanks
BigMike

[Duffil]

[threadjack] what convention Mike?[/threadjack]

[BigMike]

[threadjack] what convention Mike?[/threadjack]

It is linked on our front page, http://www.cal4wheel.com/convention/2008/index.htm