[Damo]

I've got a full rebuild kit for my transfer case, and now need to put the shims in. The manual says to says to measure the distance from the machined face to the face that the bearing sits on (for both case halves) to calculate the shim height needed.

What's the best way to measure it? I've got vernier calipers and a straight edge, which might work. Any suggestions???

[royce]

what kind of tolerance is allowed and how accurate are your verniers and straight edge?

[Damo]

royce wrote:

what kind of tolerance is allowed and how accurate are your verniers and straight edge?

Can't remember the tolerance, i'll see if I have got my manual here somewhere.

Verniers are cheapo $30 digital ones, and straight edge is a steel rule. I was thinking of taking it to an engineering place to get measured, but was hoping I could do it myself.

[royce]

I would think most engine rebuilding places would have the gear to measure it easy (good straightedge, telescoping thingy and micrometer and would do it for you or let you do it yourself for a small amount of beer

[royce]

could you assemble it with some plastigauge and work out shim size from there?

[Damo]

royce wrote:

could you assemble it with some plastigauge and work out shim size from there?

Probably, though that would mean i'd have to go get some. There should be someone around the corner from me that can measure it, i'll see if i can drop in there this afternoon.

[michael]

Digital Verniers can measure to 0.01mm depending on the type...in my experience. A garage may use Telescoping Gauges then measure that with a Micrometer...a chance for inaccuracy, but ok if they know what they're doing. Internal Mikes are better if they have them...

I'd take a punt on the Verniers...

Michael

[joeblow]

geez damo....don't go doin it properly......

[Hybrid]

I just followed the xfer rebuild details (4.9s) on the lowrange offroad site or similar. I haven't had a problem yet. Maybe we're talking about 2 different things though.

[Damo]

Well, I have all new bearings, seals, gaskets, idler shaft, thrust washers, brand new 6:1 gears and sandblasted & powdercoated the case! SO if I go and dodge up the shims i'd be a right goose! Mind you, it wouldn't be the first time I did something that stupid

Who want's to put $10 on me grenading the fawker the first time I use it in anger...

[royce]

its a 6:1, you wont even get to the tracks before it pops

dont forget the oil

[Hybrid]

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

[Damo]

I used that Trail Gear install doco, it's pretty handy. It does skip the bit about the shims though. How much difference it makes I don't really know, but i'm going to follow the FSM and hopefully my gears will survive.

Here are the relevent pages from the FSM:

[Hybrid]

Bekerk! (I believe thats the scientifically correct noise for a chicken. much harder to write than that of a moo cow)

[Damo]

Hybrid wrote:

Bekerk! (I believe thats the scientifically correct noise for a chicken. much harder to write than that of a moo cow)

Mate, you might want to check that new exhaust for leaks