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Major Tansfercase Problems

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Major Tansfercase Problems
« on: October 12, 2011, 10:40:15 PM »
So while wheeling in Low, my transfer case took a nasty hit on a rock. Now it does not go into low, and when I wrap up the motor it makes a horrible noise. It did get me home in 2 hi. Anyone have any experience with this? Looks like I will be pulling it tomorrow.

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Offline Capt

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Re: Major Tansfercase Problems
« Reply #1 on: October 13, 2011, 07:33:21 AM »
You will have a better assessment of the damages once you have it out. It's not that hard just a little time consuming with all them u-joint bolts, the floor boot, etc.

Also just check before you pull it out, pull the floor boot off, remove the shift lever, and look down into the hole and see if you can re- align the shifter fork rods and get the shifter handle guides back to "Neutral" . It may have just
Popped off the 4 wheel drive syncro output shaft as if its stock, this is a very thin gear face.

OR Now Is The Time to put that Lower gear range you always wanted, also at the same time you can up grade the 4x4 output shaft. Lowrange sells a upgrade kit for this problem,

CAPT

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Offline bentparts

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Re: Major Tansfercase Problems
« Reply #2 on: October 13, 2011, 11:12:58 AM »
What vehicle is it? Sammy, Trackick?
The usual stuff, and 2nd generation Air to liquid intercooled TURBOCHARGER

Re: Major Tansfercase Problems
« Reply #3 on: October 14, 2011, 12:29:58 AM »
its an 86 samuria. I hope to have it out tomarrow. Will update

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Offline FinishTheGame

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Re: Major Tansfercase Problems
« Reply #4 on: October 18, 2011, 07:54:22 PM »
i have an 87 sammi and will be either rebuilding or buying a rebuilt t case with lower gears, let me know how this goes.

SJ-413   mild modifications

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Offline mrdezyne

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Re: Major Tansfercase Problems
« Reply #5 on: November 01, 2011, 07:59:48 AM »
Just finished the 6.5 gear swap in my Tcase and swapped out the extra bearings not included in the kit at the same time.  Highly recomended to get the supplemental bearing kit.  Still looking for where I ordered those from though, it includes like 3 needle bearings, and 3-4 more shaft bearings that do not come with the gear swap kit.

All in all the rebuild was straight forward, it was my first time to tackle it.  Lots of little accessory parts can be found on LowRange's site, nuts, spacers, nick nacks you might need.  the instructions that come with the kit are full color and very step by step.  Good luck if you decide to break it down, mine is night and day from what it was like when I pulled it out.  (the PO had never looked at the oil level or attempted to change it, my bearings were lubed with water in the case.. HA!)

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Offline FinishTheGame

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Re: Major Tansfercase Problems
« Reply #6 on: November 02, 2011, 08:56:22 AM »
Nice. Did you get the gear kit from low range?
SJ-413   mild modifications

Re: Major Tansfercase Problems
« Reply #7 on: November 02, 2011, 09:59:45 PM »
Update. So I broke and bent the T-Case mounts and brackets. I pulled apart the T-Case and all was well. The front output bearings are making a little noise, so I replaced them. All in all I got lucky and learned a lot.

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Offline Drone637

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Re: Major Tansfercase Problems
« Reply #8 on: November 03, 2011, 04:10:08 PM »
On my SJ we beefed up the long arm by welding some angle iron on the inside then run a bolt with spacers on it.  Another person has used engine mounts from a Polaris side-by-side, that looked like a pretty solid solution.
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