[bulladean_]

Hey all I've notice backlash through the input of my 6.5 transfer case. Should I be worried ?

[jdk81]

How much backlash?

There will always be some backlash, but depends how much.
How many kms on the gears?

[bulladean_]

5mm or something. Ill have a look later.
I dont know how many. I've put 5000ks on them back I bought the transfer second hand for a good price

[jdk81]

Lock up the output.
At 90 degrees place a ruler on one of the flange yolk/drive flange bolts, and measure how far it will go.
Try it in high and low.

Ill go measure a stocky and get back to you (ill maybe do the other when i wont mind getting dirty).

[mrw82]

5mm sounds about right. Certainly nothing to be concerned about.

[jdk81]

On the outside of the flange, rough measurements in poor light.
Ill chuck a dial indicator on two stockies when I get the chance.

I got 2mm backlash in high, and 3-4 mm backlash in low

[mrw82]

Most of it will be in the dog teeth on the shift ring, backlash between gears is most likely perfect.

[bulladean_]

Yeah it roughly four to five in high and low

[jdk81]

Backlash due to dog teeth in shift ring should be same stock vs aftermarket.
So any difference would be in the gears etc.
A stock case should have a smidge more than desired for stock gears, as it has wear and tear on counter and thrust washers etc

Is it whiney?
Does it slap a bit when you accelerate or engine brake?

[bulladean_]

Yeah it is whiney and slaps when I accelerate and engine brake.

[jdk81]

Mine started doing that before it ate itself on the highway
I would be inclined to open it up. Will cost you nothing to check.


Check the thrust washers, counter shaft and inside the counter (take pics please)
Can get a new counter shaft and needle bearings from trail tough for $45 If needed.
Also possibly shim if needed (if it wasnt done on assembly).

[bulladean_]

What sort of damange\ wearing am i looking for

[jdk81]

The thrust washers will be worn, but depends to what degree.
That's the counter shaft, and failed input gear on mine.
No pics of needle bearings, if theres any signs of pitting etc, replace them.
Inside the counter gear, it can wear too.

Its possible it was assembled without the correct shims etc too...

Id love to know more info on this...

http://auszookers.com/forum/viewtopic.php?f=5&t=40562

[bulladean_]

I'm a little worried about the shimming. Don't have a clue what im doing

[jdk81]

Read the gear install guide on low range.
It tells you how assemble it and shim it etc.

You are just doing the reverse, and checking the wear and tear components.
then follow the guide to reassemble and check shims.

[bulladean_]

I might give it a good

[jdk81]

If you tear it down, and Im wrong...
you will swear at me..
put it back together and swear at me some more.
Maybe abuse me a bit more, problem over. we all learn a bit...

If you don't tear it down, and your case goes bang ...

Id much prefer I'm wrong and you're pissed at me, than you wrecking your gears.

[bulladean_]

Why would I get pissed, I dont care. Might even learn something on the way.

[jdk81]

Somewhat near worse case scenario..
If I pulled my xfer apart on someone elses advice, and it didnt need to be done.
Id probably swear and be annoyed.