[Merk]

I recently rebuilt my 6.5'd transfer case in an effort to fix a bad griding/chattering noise. I presumed it must have been the bearings, but after replacing all of them, i put it back in and it still makes the sound, this time worse.

When rebuilding the case, i noticed that there was a few mm of vertical gap between the larger counter shaft gear and both the correspoding input and output gears. The input shaft also had a bit of movement.
I bought some shims to try and fix this problem, but the shim location only serves to push the input and output shaft gears further away from the countershaft gear. The only thing i can think of is that the counter shaft shims provided with my gear kit have flattened or something, causing the gear to sit lower.
So i put the case together anyway, thinking this must be how it sits and now im back to the same problem.

The noise only occurs when in 4h, and starts as a faint grinding noise when nearing 50-60ks, and turns into a LOUD chattering noise as i back off the throttle. This leads me to beleive it must be in the output shaft, and only occurs at higher RPM.

I've called a few places around Rockahmpton (Where i live) and nowhere seems to even know what or how to shim a transfer case. So does anyone on here live in this general area or know of someone who does who knows alot about t-cases?

My next option is to swap my gears into another case and see if that helps.

Thanks for any help. I can put up a pic if anyone thinks it would help them know whats going on

[steak_knife]

Merk wrote:

Thanks for any help. I can put up a pic if anyone thinks it would help them know whats going on

Couldn't hurt, we may see some thing you may be missing.

[Merk]

Heres where the gap is at the input shaft. This pic is when i still had the bearing clips on though, so the gap ended up a bit smaller. The output shaft has a similair gap. Think this be enough to cause such a loud noise?

[MART]

If the bearing is seated properly in it's seat at the front , I'm guessing the thrust wash on the idler shaft is missing or has spun gouging the case and causing it to have play , the gear would rub on the case under load and slap back and forth as you accelerate and slow down , Need to know if thrust washer is missing , Cheers Paul.





Gears should line up perfectly.

[Merk]

That sounds like exactly what it would be! The washer must have got caught somehow when driving around and worn down.
Awesome, thanks mate
Just gotta find where to get some from now, and take the damn case out again

[Merk]

Oh wait, re-read that, and the thrust washer was definately there. That means it may have gouged out the case, shit.
I'll have to have a look when i pull it out again