Hey Mike
Sucks that the t-case install went south. can you describe the noise that
the t-case is making (grinding, slapping, etc)? Did you happen to check
all the bearings to make sure that they are good? (I know this t-case was
rebuilt, but you never know). Did you tension the chain enough (could be
chain slap)? I wouldn't drive too far with the case in this condition. You
could end up with some smooth gear cogs and metal filings littering the
inside of the case.
Russ
----- Original Message -----
From: <mike-lists@tepidcola.com>
To: <dakota-truck-moderator@bent.twistedbits.net>
Sent: Thursday, January 08, 2004 3:08 AM
Subject: DML: this is how NOT to install a transfer case
>
> don't worry if you miss something: I'll be giving lessons for a very
modest fee
> at future DML events.
>
> So I got my transfer case from Buck in Cedar Rapids today via UPS. was in
very
> good condition except for two (out of six) bent mounting flange studs. It
> looked right at first glance but it really wasn't.
>
> I had to swap output shafts becuase the case I got from Buck wasn't an HD
> model, and had a very much smaller output shaft.
>
> since it wasn't an HD, it also had a narrower chain, so when I swapped the
> output I had to change the chain and thus the front output too.
>
> then as the case whent together, I realized that I didn't have the pump
pickup
> screen in, and had to take it apart and reassemble it. and then I didn't
> connect it to the pump before reassebly, so the case had to be split
again.
>
> then the shift fork's shaft turned out to be too long (the old case used
it as
> the trigger for the 4x4 indicator, which I'll no longer have) for the old
> case's tail housing, so the shift fork had to get swapped out too - the
case
> wouldn't go all the way together.
>
> there were horrible snap rings all over without holes in their ends, just
> tapers. they were fun to play with. not. they hold all the shafts in
place.
>
> then the transfer case didn't fit! there wasn't enough room in the
> transmission tail housing for the slightly longer input shaft of the new
case.
> so the input shaft had to be swapped too, which also includes the
planetary
> set. final assembly wasn't so final when I forgot to put in the spring
that
> goes on the shift fork and had to open the case to replace that, and in
the end
> it also seems that the magnet got knocked out of the case, and that was
not
> caught until driveshafts were already in palce.
>
> when I put the old planataries in the new case, they sounded a bit noisy,
and
> that has continued in a rather severe fashion now that the truck is put
back
> together. I'm a big non-fan of rather loud gear noise right under my
feet.
>
> I was incredibly thankful for the help of two friends. I don't think I
could
> have made the half dozen (maybe seven or eight...) splits and reassemblies
for
> parts-swapping and mistakes without them, and they made final reassembly
under
> the truck drastically quicker. Even so, from my start at about 16:00, it
was
> about a 9 hour job (Nick and Justin showed up around 19:00), and the quick
test
> drive I made only led to more questions of noise.
>
> The shift linkage still needs adjustment, and I'm going to recheck the
fluid
> level.
>
> Before I knew of the horrible noise I'd planned to put on a couple hundred
> miles in the next few days, change the fluid and call it good to go. but
this
> gear noise has me rather concerned. is it possible that just the lack of
> hundreds of thousands of matched meshing has caused the planetaries from
on
> case to make noise with the ring from the other case? that's my
assumption
> now. consequinces? is it going to blow up halfway across Ohio again?
Should
> I park the Dak for spring semester instead of parking the RamCharger?
>
>
> I really would like some input on this. and I also know that gear noise
means
> gear wear, and I'm pretty sure that I'm missing my magnet from inside,
which is
> Not A Good Thing.
>
> in summation, AARGH!
> --
> Mike Maskalans
> semi-borked '98 CC Dak
> '84 RamCharger
>
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