10 replies to this topic

[Bigremi]

I feel stupid
My transfer case feels like it is getting stuck on the bearing of the input gear.
I've been avoiding hitting it hard with a hammer but is that what it needs?
Why else would it not install?
Video of me trying to install it: https://youtu.be/dT-...egKya0_fduDXqPB

Hard to see in the video but there is an aprox 7mm gap at the bottom i cant close

The transfer case is from another car because mine had a large crack in it

[viz139]

Have you fitted a new bearing and outer race  or transferred the old race to the new housing.  If not remove the bearing and make sure it fits into the race, you may have a mismatched set. Best to fit a new set.

[KTS]

difficult to tell, but is the bottom locating pin correctly seated ?  it looks to sticking out a bit more than it should....

 

unless you want to knacker another case i wouldn't hit it with a hammer..

[imack]

Often the lower rollers in the bearing on the input shaft hang down slightly and foul the outer race in the transfer case. Try smearing some wheel bearing grease on them to stick them to the inner race before trying to install the transfer case.

[Spider]

Often the lower rollers in the bearing on the input shaft hang down slightly and foul the outer race in the transfer case. Try smearing some wheel bearing grease on them to stick them to the inner race before trying to install the transfer case.

 

99 times out of 100 this ^ is what I find dose it with used Outrigger bearings.

Imack's suggestion of grease is good, another method I use is to roll the idler gear around as the case goes on, the outer ring for the roller bearing has a small taper on it and by rolling the bearing over, the rollers seat back in place.

[nicklouse]

Why can’t people post useful photos?

 

as mentioned are the bearing sat in the race and not just hanging.

[bpirie1000]

What does the inside of the transfer casi g look like?

Measure everything....

[Bigremi]

So i managed with great effort to pry the bearing races from both housings, the inner diameter of the new one is 0.3mm smaller than that of the old one

When trying these on the bearing the old race fits and the new one doesn't. So I'm happy to declare that the problem  20250611_193805.jpg   25.84K   0 downloads  20250611_193805(1).jpg   31.42K   0 downloads

[mk3man]

take the 2 top drop gears off then try to fit it, is the center drop gear the same length ether side that sits in the bearings in the box and housing? or remove the line up plugs then try to fit it, remove the bottom bearing to see if it fits in the race that's pressed into the case.

[mk3man]

haha started writing that before the last post.............

Edited by mk3man, 11 June 2025 - 08:11 PM.

[Mr Piggy]

It looks like you have 2 thrust washers on the outside of the idler gear.