Rockcrawler tcase install

[evergreen]

This is not a step by step write up, it only shows that you can do the install in your garage.

A few members of pnwx (rrdstarr, chuckh, schlud, synchro) got together a few weeks ago to do the install of calminis new 3.92 to 1 transfer case gears.

first off we removed the torsion bars and torsion bar cross member as well as the exhaust hanger right behind the cross member. also disconnect all electrical hook ups to the tcase. also drain both the tcase and transmission.



next we removed the front and rear drivelines and removed the shifter linkage to the tcase.



then get a transmission jack under the tcase and begin removing all the bolts where the tcase meets the transmission. the top bolts have to be removed from above by lifting the shifter boot housing in the interior. after all the bolts are free get a long screw driver and a rubber mallet and break the case loose from the transmission. the transmission jack is very handy since the case is heavy and not easy to balance.



once you get the case out you can finally start using the calmini instructions. the directions skipped a few small steps but its pretty easy to tell what bolts need to be removed on the back half of the case. the pictures with the instructions are great in guiding you along.
get the case on the floor and start removing the housing bolts and popping the seals. be careful not to damage the input shaft, a thick blanket on the ground is good.



once the case is apart the directions tell you what needs to be removed and which parts of the case need to be ground down. you have to reuse the some of the bearings and install one new bearing. here is what the new 4lo gear looks like with the bearings pressed on.


using paper plates and an ink pen work great to seperate nuts, bolts and everything else. pizza crust doesn't go into the tcase


there are alot of small parts in the case, the neutral check balls are easy to lose so be careful and take your time when dealing with the inside of the tcase.


install the new gears, bearings, and housing shim. reassemble the housing using plenty of rtv sealer.


letting the sealer dry overnight is a good idea. then reinstall the case and reassemble the truck. fill the tcase with the supplied gear oil and refill the transmission. your now done. time for BEER!!



the gears are expensive, but they are worth it the first time you get it in 4lo. the gear reductions will blow your mind!! 4lo 1st gear at 3500rpm is about 2mph.
4hi is unchanged.

a good set of hand tools, a cutting tool, lots of swearing, and a few buddies is all ya need to do this in your garage. the only thing that most people don't have is a bearing press which can be found at dealerships and machine shops. usual labor rate is about $40 for them to press the bearings.

[rrdstarr]

Looks good Mikey!

[Schludwiller]

Those gears are out of control. When Mike let me drive his truck, I almost idled up a rock pile, then on the descent had to give it gas to keep from stalling.

Glad we have a test-pilot. They're on my list, and now we know we can do it right.

[evergreen]

Originally Posted by Schludwiller

Those gears are out of control. When Mike let me drive his truck, I almost idled up a rock pile, then on the descent had to give it gas to keep from stalling.

Glad we have a test-pilot. They're on my list, and now we know we can do it right.

should be alot easier the second time around now that we know what to expect.

[OffroadX]

Cool. Between your posts and seeing Calmini's instructions it doesn't look too tough.

What's Synchro up to these days anyway? Haven't heard from him in ages.

Brent

[Schludwiller]

Originally Posted by OffroadX

Cool. Between your posts and seeing Calmini's instructions it doesn't look too tough.

What's Synchro up to these days anyway? Haven't heard from him in ages.

Brent

That's one reason for the pics. We couldn't find any on the internet to help in those "vague" moments of the work. It's a two day job if you don't rush anything, which you don't want to do with new gears.

We've gotten Synchro on two runs so far I think (I was on one). It should be interesting when we get the rain and wet clay/mud here. We've got lots of twisting offcamber trails through trees that make for their difficulty rating (most trails here have two ratings, one for dry, one for wet). Kirk doesn't like offcamber stuff.