Transfer case rebuild question

[Spoot]

Pulled the t-case to replace the plastic fork since I was having the binding problem on turns. Seemed like a good thing to do since I was also pulling transmission to replace clutch.

Split the case and the didn't keep track of the gears and belt, so got a new belt.

When I put the case back together, I can turn the spindles and move the forks through the positions, case is maybe 1/4" gap between the halves. When I pull the case together, I can no longer turn the shafts without a lot of effort. Reading around, I see folks talk about turning the spindles and testing the positions, seems like they're able to do so with the case closed. Any ideas? I used the Schwartzy manual to reassemble the box, so I think I have all of the gears and washers in the right places. Any odd gear alignments that aren't really clear in the manual I should check? Any other ideas?

I used the gasket as a template to cut holes in some plywood and bolt the lower case to it so I have a good case holder.

Thanks!
JD

Sent from my SM-N950U using Tapatalk

 

[H3Hummer]

This is important for the T-case reassembly !!

https://www.youtube.com/watch?v=q3f-9ABFsj0

Did mi shift fork replacement, just kept the chain in same place with white marks on it and everything is working great.

 

[Jeepwalker]

I would FOR SURE consider knocking out and replace the output shaft bushing (rear driveshaft) while yer in there. Easy to knock out from inside the tail. If you already have it together, you could take it to the dealer and they have a special tool that can easily pull out the old one and install a new bushing. Mine had fair amt of free-play and a new bushing did the trick.

 

[H3Hummer]

I would FOR SURE consider knocking out and replace the output shaft bushing (rear driveshaft) while yer in there. Easy to knock out from inside the tail. If you already have it together, you could take it to the dealer and they have a special tool that can easily pull out the old one and install a new bushing. Mine had fair amt of free-play and a new bushing did the trick.

That's right dude, i did mine with the help of a buddy and his 20 ton press, he also has some tools that i miss in my personal work bank :giggle: and everything is easy with a press:wink:

 

[Spoot]

All back together. The video was helpful in showing how to line up the notches, didn't know that was a thing. Key to the fix was turning over the drive sprocket.

Curious about the output shaft bushing, that doesn't touch the shaft, how does it help keep the shaft from having play? You're talking about the one near the rear output shaft seal, right? Mine seemed in good shape.

Thanks!
JD

Sent from my SM-T860 using Tapatalk

 

[Jeepwalker]

It does touch the driveshaft yoke. If the drive shaft yoke has play then then the bushing's worn. If there's a decent amt of 'freeplay' that can increase wear inside the xfer case. Like I mentioned above, there's a special Kent Moore tool the GM dealers have to remove and reinstall the bushing on the vehicle. The manual tells the part number of the tool is J-45380 (there are different size for different vehicles). It works slicker than slick, takes minutes. My dealer let me use theirs, which surprised me, it's a $500+ tool. If yours is tight... then no worries. If not, better to take the xfer in so they can change it on the bench vs have to put the car on the hoist. Cheers!

https://www.freedomracing.com/output-shaft-bushing-remover-installer-j-45380-u.html

 

[Spoot]

Got it. Had my head still inside the transfer case, wasn't thinking about the yoke. It's solid, so good on that front.

After a few trips around the block, still feels like it all came back together right. Another good learning experience!

Sent from my SM-N950U using Tapatalk

 

[Jeepwalker]

Yeah!!

:yay

 

[H3Hummer]

Got it. Had my head still inside the transfer case, wasn't thinking about the yoke. It's solid, so good on that front.

After a few trips around the block, still feels like it all came back together right. Another good learning experience!

Sent from my SM-N950U using Tapatalk

:horns: