[Saam]

do you have to take the speedo drive out to get the main shaft out ?

also how do i get it out, and i hope i have not broken it i completely forgot about it because i am an idiot and have been bashin the main shaft for a little bit it did start to move i hope i have not got the speedo gear and shaft stucked in there

everything else is going beutifully this is the only bearing left to get to

[brendan]

thats a coily tcase?

if its a WT tcase you wouldnt happen to know the size of the input seal? just got my seal but i dont think its the right one he didnt seem to know alot. so if you got some mesurement i might eb able to see if its going to work without taking th case out. also do you need ot split the case the change the input seal or just take the yoke off?

[Saam]

just take the flanges off all the seals are easy to get to, this is a wt case i am doing as we speak, the input shaft and front output have the same larger seal and the rear output shaft (pictured) has a smaller one.

[brendan]

ok thanks so just take the flage off and i can change them? are you able to give me the outside mesument of the input seal?

[Saam]

yeah you should be able to pry them out.

i think i have fucked this transfer, pretty sure i managed to bind the speedo gear and the main shaft up, going to take a fucking miracle to fix this

[brendan]

yer i did that too i am shure the whole lot comes out? i have forgot now. can you give me an the outside mesumnt of the input seal?
and by pry them out you mean its not the way it should come out? if i remeber right i should be able to change the seal without cracking the case open

[Saam]

pry is the word you use in regards to take the seal out.

they are in the outside of the case so thats the way they come out.

outside diametre is roughly 60 mm.

i just can't get a hold of this speedo gear, everything else has worked easy for me

[brendan]

use multi grips and some wd40. remeber i am not 100%shure it comes out
i have forgot. anyway new seal is in

[brendan]

STILL LEAKING!!!!!!!!!!!
lucky i got 1 more seal left. going t take the case out and do it this time to make shure there are no burs on the seal seat. i put grease around the seal and its a genui suzuki seal and it still leaking! the tcase was only just rebuilt with new bearings gears and seals no long ago then all of a suden it started leaking!

[Saam]

weird hope that doesn;t happen to mine, maybe shaft is worn or some shit.

ANYWAYS NEXT QUESTION

does this main gear (the big one) need a shim or something ? should it move it has about 1 - 2 mm side movement.

so speedo gear then shim, that shim has movment and so does the gear next to it.

[brendan]

i would say it would probably need a shim

[Saam]

so far one vote for shim and one for maybe not on outers lol come on where are the gurus

[lump_a_charcoal]

Shim for PM!

[Saam]

ive got way more answers for thats just how they are meant to be at this stage lol

[Damo]

I don't recall needing a shim there.

Have a search for transfer case posts by me, I posted a PDF copy of the factory manual rebuild guide somewhere.

And if you haven't guessed already yes you do need to take out the speedo drive first.

[Saam]

yeah got past the speedo fiasco lol it was just a stupid noob move i made

[Saam]

okay so from reading all the stuff damo has posted up and looked at all the pretty pictures for some reason my speedo drive gear seems to be to far along the shaft, so looks like i will have to bash it up snug with the big gear spacer. And looks like i will have to check out the shim action seeing as i can not understand how this could be wrong unless i managed to move it when i forgot to take the speedo gear out.

[hooki]

http://www.trail-gear.com/tech/zuk65gears/index.html

that link might have some helpful stuff in it for you, just ignore some of the stuff required for 6.5:1 gears.