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....
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.