[Blkfxx]

Worth replacing? I'm thinking yes.





Should I also replace the needle bearings?

[greyghost]

without a doubt replace both the shaft and bearings

[jdk81]

What is the inside of the counter like?

[Blkfxx]

[JrZook]

Counter gear looks like it has damage too. What gear set is that from? Stock?

[Blkfxx]

6.5s.

[jdk81]

How many km?
As above the counter gear looks a little worn, the worst areas should be close to the outside of the counter, how does it feel on a finger nail?

How worn were the brass thrust washers?

[Blkfxx]

Under 10K, The only part noticeable (not greatly) to the finger nail is the change from where is doesn't look worn to were the lines start on that top pic, On the outside.




I only used the shim that came out of the case when the gears went in. Noob move on my behalf but the TG instructions that came with the gears didn't mention it nor did the Drover FSM from http://www.suzukiinfo.com/ I now realise it should have been done.


Let me know if you need any more info or pics.

[jdk81]

If there is no noticeable step i.e. very little material removed, id say its normal wear and tear.
New needle bearings, thrust washers, counter shaft and put it back together, and it should be fine.

How much meat is worn out of the worst thrust washer?

Ive done a tiny bit of reseach into xfer cases etc.
From some torque loading calcs, changing the gears changes the leverage on counter gears, which increases the loads on the needle bearings and surface faces (for the bearings) of the counter shaft and counter gear.
Which means these wear out quicker, how much quicker im not really sure, at this stage. There is very little information on it and I dont think anyone has really looked into it.

The counter gear is a wear and tear item, and is the only component that can not be replaced easily. This means all gears will fail eventually (the lifetime warranty on 6.5s from LROR is very valueable).

The only way to prolong the life of a gearset is to inspect and/or replace the thrust washers and counter shaft and needle bearings on a regular interval.
The interval should be shorter than regular stock components, because the loading is a lot higher.

Unfortunately it's going to be trial and error for us to get a better understanding of sensible service intervals for aftermarket gears.
Aftermarket gears are an investment and worth protecting, and will take some effort from others to try and develop a better understanding.

Once you get it back together, can you check the backlash in high and low.

I wish everyone would check backlash of their cases, listing backlash, gear ratio and km done.

[Teracis]

I can check the backlash in my case with 6.5's tomorrow afternoon but you're only going to get a rough measurement from me as all I'll be able to do is measure the flange movement when holding the input flange still, by measure I mean measure the amount of rotation at the edge of the flange with a tape measure by drawing a line on it.

Is there a better suggestion?

[Blkfxx]

jdk81 wrote:

If there is no noticeable step i.e. very little material removed, id say its normal wear and tear.
New needle bearings, thrust washers, counter shaft and put it back together, and it should be fine.

I can't feel a step, Only a difference in the 2 surfaces, If you get what I mean.

jdk81 wrote:

How much meat is worn out of the worst thrust washer?

Photo makes it look worse than it is




Does anyone know if the needle bearings are going to be easy to get a hold of? Are they a common size?

[jdk81]

Order a shaft and needle bearing, and thrust washer kit.

Trail tough kit is the go
http://www.trailtough.com/index.php?pag ... &Itemid=53

[Blkfxx]

Already have new thrust washers and I've got a counter shaft on the way, Just need bearings. :/

[Daves4wd]

Message 4wdproducts on eBay he sells genuine needle bearings. I bought his rebuild kit and the only bad thing in it was the input output seals