[Scales]

Hey all,

Ive got the wt swap conversion done now finally on my Jim, and took him out for a squirt after flushing the oil a few times. Seems pretty good, no epic whines or anything.

However i do have a sort of rattle when i put my foot on the clutch and just coast along, it also happens when i clutch in to gear up/down etc. It sorta sounds like a bit of end play or slack in the gears. I wasnt expecting a pristine case when i got it, Would it have something to do with the shims or something? Would buying one of these rebuild kits would be the go? and has anyone done it themselves without much drama? i dont have a press, but almost every other tool.

I dont know much about gearboxes, im more a electrical sorta guy so any further explanation of whats going on here would be much appreciated! and thanks for all your help up till now also

http://www.ebay.com.au/itm/Transfer-Cas ... 663wt_1163

[suzooky87]

Check your drive shaft splines and universals.

[Scales]

yep done that, look good to me. no slack.

[31zook]

Welcome to a 25+ year old tcase.

I would rebuild it and check your tolerances.

[JrZook]

Most likely the thrust washers have worn inside the case causing some backlash

[Scales]

okay so ill go and get that rebuild kit.
is it a hard task to do? or easy weekend job? any special tools req'd?

[Scales]

well thats different,
I just got my new shifter bush in the mail (thx Bruce) and re-installed the spring retainer (what a PITA that is!!!) and most of the rattle seems to have gone.... I guess the shifter rods rattle about a bit.
However it does sound a little rough still so i probably should get the case re-built with new bearings etc.
any advice from someone whos done it?

[SierraDan]

It's an easy job I spent a weekend trying to fix a case and now I can do a drive in drive out rebuild in an hour, it's just practice. The noise will likely be solved by new shims either end of the countershaft.

[Scales]

righto dan, so would you recommend buying that kit i linked? or just some shims?

[SierraDan]

If you can afford it, you might as well rebuild it while it's apart.
And that kit has new shims in it, they're the ones with triangle shaped holes.

[xedent]

I have noticed that my Sierra does the exact same thing after I put in my 4.9's with all new bearings etc
Mine happens if I'm accelerating in 1st then drop to neutral then coast?

[zukenutter]

Both transfers I have make the same noise. I think there are actually two noises blending together.

A: slop in the counter shaft from worn counter shaft thrust washers as already mentioned, and/or a need for shims on the input and/or output shafts.
B: chatter in the transfer lever due to worn bush.

You've solved (B) already, I should do that too. I installed one one the first case but forgot about the second

From experience so far (Not much but probably enough ) I've realised that non-genuine counter shaft and thrust washers can be a waste of time.

Don't know if you've seen this? You'll see I have had the same issues.
http://www.auszookers.com/forum/viewtopic.php?f=5&p=402353#p402353

_____________

Also, to reinstall the the spring retainer I made this...
http://www.auszookers.com/forum/viewtopic.php?f=14&t=22902&p=404220
The next time I use it I'm going to notch the ring so the shaft will pass through it instead of having to slide it down over the shaft.

[31zook]

another option is the slines used in a sierra jack shaft and a jimny gearbox might just be a touch different... thus causing a little noise.

mine does it to.... also has a small click when going from on the gas to off the gas, which is my rear disconnect doing that....

[zukenutter]

31zook wrote:

another option is the slines used in a sierra jack shaft and a jimny gearbox might just be a touch different... thus causing a little noise.

mine does it to.... also has a small click when going from on the gas to off the gas, which is my rear disconnect doing that....

Both of my cases do that.

[zukenutter]

Also of note regarding transfer noise. The bolt through bushes magnify the noise through the chassis and body, I've swapped to stock bonded bushes.

[Scales]

the bushes supplied have changed a little i think, might be a bit softer and quieter. they are a soft black setup, not that orangey stuff like in monkeys thread.

I had the shifter boot off so i could see straight through the car when i was testing, and it was definatley a noise from the case, not the shafts.

im not really keen on forking out 300 for the rebuild kit. I kinda agree with the shim/thrust washer idea. where can we get those on their own?

1 question wtf is a counter shaft? lol

[Scales]

zukenutter wrote:

Don't know if you've seen this? You'll see I have had the same issues.
http://www.auszookers.com/forum/posting.php?mode=edit&f=5&p=402353

.

Links shagged mate.

i did see that tool and was thinking of you when i was putting the poofta in. ended up with the 2 screwdriver trick and it just... worked.. after like 20 goes at it.

[monley]

Scales wrote:

zukenutter wrote:

Don't know if you've seen this? You'll see I have had the same issues.
http://www.auszookers.com/forum/posting.php?mode=edit&f=5&p=402353

.

Links shagged mate.

i did see that tool and was thinking of you when i was putting the poofta in. ended up with the 2 screwdriver trick and it just... worked.. after like 20 goes at it

I do mine from under neath just by pressing down on the little cup thing and twisting....seem's to be the easiest way of doing it for me any way.

My t-case make's all sort's of weird fuked up sounds...i just turn the music up New t-case should be less noisy i hope hey 31zook

Also any pics of the new black bushes you got in your kit? I think they are responsible for 75% of the noise coming into the cab

[SierraDan]

Haha, PUT NEW SHIMS IN ANDREW. It's a cut and welded/bolted gearset it needs new shims and extra ones.

[monley]

SierraDan wrote:

Haha, PUT NEW SHIMS IN ANDREW. It's a cut and welded/bolted gearset it needs new shims and extra ones.

I will when i rebuild it for the other project It's pissing out oil some where to...can't firgur out where tho Diff breather maybe?

[zukenutter]

Scales wrote:

zukenutter wrote:

Don't know if you've seen this? You'll see I have had the same issues.
http://www.auszookers.com/forum/posting.php?mode=edit&f=5&p=402353

.

Links shagged mate.

i did see that tool and was thinking of you when i was putting the poofta in. ended up with the 2 screwdriver trick and it just... worked.. after like 20 goes at it.

OOPS

Fixed!!

http://www.auszookers.com/forum/viewtopic.php?f=5&p=402353#p402353



The problem is more so the Bolt Through design of the bushes. Only problem with the stock bushes is it moves around a bit more.
I did notice that your's are black, are they rubber or urethane?

[Scales]

they feel like rubber. not 100% on that though
I can squish them with my fingers a little, put it that way.

When you split the case that time, did you do it just for the thrust washers? where did you source them? EDIT: just saw suzistore, 9 bucks each.

Im just trying to decide between buying only the washers or fork out for the kit. Its pretty exxy for something that could be 100% fine anyway, bearings i mean.

if its not a big effort whipping it out and splitting etc etc, i might just go for the washers to see how it goes. Thoughts?

[31zook]

I'm pretty sure you an get bearings cheaper from other places

And Monley, soon soon

[SierraDan]

The effort of replacing the washers is about 80% of the effort of a full rebuild in my opinion.

[zukenutter]

SierraDan wrote:

The effort of replacing the washers is about 80% of the effort of a full rebuild in my opinion.

Are you joking? Takes very little time to split the case and change the counter shaft, needle bearings and thrust washers. Replacing the rest of the bearings takes a lot longer and much more involved.

I'd suggest just try the replacing the counter shaft, needle bearings and thrust washers first. If it's still no good at least you'll have a better idea of what's involved.

[SierraDan]

Like I said, in my opinion. Pulling and pressing the bearings takes no times at all.

[zukenutter]

SierraDan wrote:

Like I said, in my opinion. Pulling and pressing the bearings takes no times at all.

What's your trick? Seriously, would be nice to make this job much easier next time.

[SierraDan]

Practice mostly.

But I use a bearing puller with a rattle gun to take bearings and gears off in seconds.
6t press to put them back on.
As I said earlier in the thread, "drive in drive out" would take me less than an hour.

If he can easily afford to get the full kit he might as well do it once and not have to worry about it for years, or do half the job and pull it out again later on.

Just my opinion

[zukenutter]

unless he doesn't have a press, bearing puller or rattle gun. Just my opinion.

[SierraDan]

Then it takes an extra 20mins