[bron5on]

Starting to think I've invested in nothing but problems with the tcase I bought the other day. I replaced a detent bolt,spring and ball as mentioned in my previous thread. Need to replace the ball under the reverse 4wd switch when I pull the other transfer out so that should hopefully fix my loose shifting feel. However, i have noticed a few more bolts missing. One between the 2nd and 3rd casings on top of the transfer, one securing the locking tab for the counter shaft (including tab) and one securing the first and second casings on the bottom of the transfer. Now the first 2 should be easily fixed, i'll just rob the parts from my other transfer (I think this case hase been robbed of a few bits in the same fashion). The third is a different can of worms tho. You can see the missing bolt in the following pics.


The view of the front/bottom of the case. You can see the missing bolt (or at least the hole it came from!)


And a close-up of the hole.


Now my drama is that there is no thread in this hole! Not even any remnants of a thread! I'm guessing it has been completely stripped. Now I figure I have 3 options available to me with varying degrees of dodginess.

1. I leave it as is, will probably leak oil tho and I risk killing the box if i don't keep an eye on it. Most dodgy.

2. I tap a new thread into the second casing and fit a slightly larger bolt. Not sure how easy it will be as the hole doesn't seem to go all the way through the second casing meaning I can only get a tap in there so far. Not as dodgy.

3. Swap the gears into my other case or rob the second casing from it and install onto this one. Probably least dodgy but considerably more effort which is why i forked out for a case that already had gears instead of importing gears from low range and trying the install myself. This is beginning to be a headache.

Any ideas guys?

Bronson

EDIT: Scratch most of that guys. Upon closer inspection I have decided the bolt has been snapped off at the start of the thread. This is gonna be fun....

[Junior_91]

Looks like the bolt is still in there mate and has been snapped off.

EDIT: Just saw you realised that mate you should be able to get it out.

[bron5on]

Junior_91 wrote:

Looks like the bolt is still in there mate and has been snapped off.

EDIT: Just saw you realised that mate you should be able to get it out.

I hope so matey. Never seen let alone used easy outs. Will I be able to fetch it out using them? The thread is in there about 20mm. Will I be able to get to it? Or do i need to take the front housing off to get a little closer?

[v.w.dave]

Option 3 mate.... piss off the tapped out case and use youe case then you will have no worries....

[Taff]

Just use an ezy out. They work pretty well.

If that doesnt work then swap the gears over, install it and never have to worry about it again.

[MART]

Is the bolt snapped off or is the thread stripped < Cheers Paul.

[lump_a_charcoal]

Mate you can pick up another case pretty cheap - Yours is a basket case, and only good for scrap IMO.

[bron5on]

MART wrote:

Is the bolt snapped off or is the thread stripped < Cheers Paul.

It actually looks to have snapped off. Will find out tomorrow if I can get it out. My little brother is taking it to work to have a crack at it. Will see how he goes.

[bron5on]

MART wrote:

Is the bolt snapped off or is the thread stripped < Cheers Paul.

It turns out that it was both. The bolt came out (what was left of it) but the thread in the case is rooted. It had been locktited in there pretty good. Think I have bought a dud. Not real impressed. It came from a fellow auszooker too. My brother had it apart and said it is a bit of a mess inside the case. Isn't shifting well either and that is after I replaced the bush under the shift lever. Sometimes the lever jams in one spot. The outputs both turn together but independantly of the input. Each time I take the lever out and have to re-align the shafts to get it shifting properly again. Dont think this case will be going in the car. Was looking forward to having gears too. I might still be able to make one good case from this one and my standard one.

[MART]

Have you checked that the detent balls and springs are there , ie , the shift rails lock in position and has the centre detent ball been removed to allow low 2 shifting , I would strip the standard case and put the gears in only if there OK . Don't use silicon on the gaskets , purchase new gaskets and use permatex , aviation gasket goo , most spare parts shops sell it. Wash every thing down in diesel , shouldn't cost much more , you will need access to a press , to change the gears or if your happy with the shafts just simply swap it into the new case , good luck , Cheers Paul.

[bron5on]

MART wrote:

Have you checked that the detent balls and springs are there , ie , the shift rails lock in position and has the centre detent ball been removed to allow low 2 shifting , I would strip the standard case and put the gears in only if there OK . Don't use silicon on the gaskets , purchase new gaskets and use permatex , aviation gasket goo , most spare parts shops sell it. Wash every thing down in diesel , shouldn't cost much more , you will need access to a press , to change the gears or if your happy with the shafts just simply swap it into the new case , good luck , Cheers Paul.

Thanks matey. I'll take the case apart and give it a good inspection and clean and see what I can salvage Hopefully the gears and shafts will be ok so that I can swap them accross. Next time I'll go for new stuff! Cheers!

Bronson

[bron5on]

So I finally got around to taking this case apart. Gears and shafts look ok so I will swap the lot into my existing case. I found the reason for the sloppy shift feel between 2H and 4H. I had 4 detent balls. The one acessed from the external was in the right place, one of the inners was in the right place and there were 2 just floating about inside the case. What i need to know is can i clean everything with kero or should i use diesel as stated above. Can i clean the needle bearings as well providing i give them time to dry? Not replacing bearings just yet as the zuk will be shedded soon for upto 12 months before I decide what to do with it (I'm almost out of a job due to being made redundant so we're going on a fishing trip for 12 months ). Also what grease should I use on the bearings? Thinking i'll need something reasonably tacky that I can use to hold the shims in place when I put it all back together. Cheers guys.

Bronson