1G 1G DSM 23 Spline Transfer Case turning torque and backlash

[all black 4G63]

Hello,

I recently rebuilt my transfer case from parts of spare t-cases layin around. I replaced the drive gear preload taper roller bearing ( this is the bearing on the input spline side of the case). This is the only bearing I replaced and was sourced from Autozone since I could not find the OEM one. I then replaced all the seals and re-assembled per the service manual specs.

My question is; the input shaft drive gear turning torque per the service manual is 1.23 - 1.81 ft.lbs. (input drive gear side) this seems really tight to me? I am actually right at 1.23-1.25 ft.lbs. which apparently is within spec. However, I feel as this will smoke my viscous coupling for some reason and put strain on my trans? I can't turn the shaft my self by hand it is that tight!

My back lash is within spec right .0031" and I honestly could not get a god contact pattern reading, but it seemed ok.

how stiff is this case supposed to be after setting the tolerances. Did I do something wrong? is this the result of replacing only one bearing and reusing the other 30 year old ones? is it super tight due to not wearing in with the proper oil? am I just paranoid? sorry for all the questions, like everyone one else with these cars I have WAY too much time and money into it to allow my trans to smoke because of these t-cases..

Thank you for any input!
Anthony

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[We're on Boost]

Cool torque wrench, so I looked up Proto Dial Torque Wrenches in-lb and I see they make even a smaller one. Glad to know about them.
Wait though, 1.25 ft-lbs is 15 in-lbs and it looks like the wrench is reading 24 in-lbs. Is 24 in-lbs actually what it's set to? (2.0 ft-lbs)

 

[all black 4G63]

Hi " we're on Boost" thanks for the reply.

The wrench is set to 24 in lbs (blue dial) because that would indicate 2 ft.lbs. after turning and would be outside spec.

So you can see that the turning torque is actually 12-13 in lbs which is the (orange dial). Apparently 12-13 in lbs or 1-1.2 ft lbs is within spec, but it just feels tights as hell almost binding.

thank you

 

[We're on Boost]

Ahh I see there is a yellow needle there pointing to 12.
Well, did you happen to see another thread "Weird sound and clutch issues" starting in post #11 the person had a similar question and we eventually got Tim Zimmer into it. So that would be good to look at.
Anyway he couldn't turn his with his fingers. I could turn my old one with my fingers but it was really hard.
He found later he could turn his much easier with the tail section taken off.

https://www.dsmtuners.com/threads/weird-sound-and-clutch-issues.535301/

In post #19 another user says his is hard to turn by hand.

To me, the 1g FSM is pretty vague about how to measure this torque. On page 21-130 it looks like they are measuring with the t-case put together, seals and everything. But on page 21-133 it looks like they are measuring with the tail section (extension housing) taken off. So anyway I don't know really the answer for your case but thought I'd just throw in those comments. It seems though like your turning torque is correct and you've got an actual good torque wrench on it!

​

 

[twicks69]

Coming over from the other thread I was pulled from....

What does the contact pattern look like in both directions? What thickness inner backlash shim is being used for 0.0031" BL? What is the thickness of the side cover shim? With the bolts torqued you are saying it is binding, so, loosen the side cover bolts and see how it changes in feel by slowly hand tightening them, is it binding because of excessive bearing preload, or is it binding because the gearset is not set up properly for pinion height or pinion preload?

If we are determining that it is side cover bearing preload being set too high, remove the side cover, remove the bearing race and shim, install some 3/32" diameter solder pieces evenly spaced in the cover with some petroleum jelly, then reinstall the bearing race, and then reinstall the side cover and bolts tightening them evenly to 29 ft/lb. Let sit in room temp (like 68*-72* type room temp, not super cold as that will affect numbers). Now, turn the drive gear and see how it feels, this would be a zero preload value. If it is still binding you likely have a pinion height issue, but still confirm. Simply remove the front housing from the mid housing (measure the mid housing spacer plate shim and be sure to reinstall a good mid housing o-ring), then do the turning feel again. If it is nice and easy, then pull the side cover off, remove the bearing race and measure the solder thickness.

Shim list below -

Part Description		Part #		ID Number		Thickness (mm)
Transfer Case Inner Drive Backlash	-	MD746510	-	0.0421​	-	1.07
Transfer Case Inner Drive Backlash	-	MD746511	-	0.0433​	-	1.10
Transfer Case Inner Drive Backlash	-	MD756755	-	0.0445​	-	1.13
Transfer Case Inner Drive Backlash	-	MD756756	-	0.0457​	-	1.16
Transfer Case Inner Drive Backlash	-	MD756757	-	0.0469​	-	1.19
Transfer Case Inner Drive Backlash	-	MD756758	-	0.0480​	-	1.22
Transfer Case Inner Drive Backlash	-	MD756759	-	0.0492​	-	1.25
Transfer Case Inner Drive Backlash	-	MD726167	-	0.0504​	-	1.28
Transfer Case Inner Drive Backlash	-	MD726168	-	0.0516​	-	1.31
Transfer Case Inner Drive Backlash	-	MD726169	-	0.0528​	-	1.34
Transfer Case Inner Drive Backlash	-	MD724326	-	0.0539​	-	1.37
Transfer Case Inner Drive Backlash	-	MD724327	-	0.0551​	-	1.40
Transfer Case Inner Drive Backlash	-	MD724328	-	0.0563​	-	1.43
Transfer Case Inner Drive Backlash	-	MD724329	-	0.0575​	-	1.46
Transfer Case Inner Drive Backlash	-	MD724330	-	0.0587​	-	1.49
Transfer Case Inner Drive Backlash	-	MD724331	-	0.0598​	-	1.52
Transfer Case Inner Drive Backlash	-	MD724332	-	0.0610​	-	1.55
Transfer Case Inner Drive Backlash	-	MD724333	-	0.0622​	-	1.58
Transfer Case Inner Drive Backlash	-	MD724334	-	0.0634​	-	1.61
Transfer Case Inner Drive Backlash	-	MD724335	-	0.0646​	-	1.64
Transfer Case Inner Drive Backlash	-	MD724336	-	0.0657​	-	1.67
Transfer Case Inner Drive Backlash	-	MD724337	-	0.0669​	-	1.70
Transfer Case Inner Drive Backlash	-	MD724338	-	0.0681​	-	1.73
Transfer Case Inner Drive Backlash	-	MD724339	-	0.0693​	-	1.76
Transfer Case Inner Drive Backlash	-	MD724340	-	0.0705​	-	1.79
Transfer Case Inner Drive Backlash	-	MD724341	-	0.0717​	-	1.82
Transfer Case Inner Drive Backlash	-	MD724342	-	0.0728​	-	1.85
Transfer Case Inner Drive Backlash	-	MD724343	-	0.0740​	-	1.88
Transfer Case Inner Drive Backlash	-	MD724344	-	0.0752​	-	1.91
Part Description		Part #		ID Number		Thickness (mm)
	-		-	SAE	-	MM
Transfer Case Outer Drive Bearing Preload	-	MN168245	-	0.0386​	-	0.98
Transfer Case Outer Drive Bearing Preload	-	MN168246	-	0.0421​	-	1.07
Transfer Case Outer Drive Bearing Preload	-	MN168247	-	0.0457​	-	1.16
Transfer Case Outer Drive Bearing Preload	-	MN168248	-	0.0492​	-	1.25
Transfer Case Outer Drive Bearing Preload	-	MD723600	-	0.0528​	-	1.34
Transfer Case Outer Drive Bearing Preload	-	MD723601	-	0.0539​	-	1.37
Transfer Case Outer Drive Bearing Preload	-	MD723602	-	0.0551​	-	1.40
Transfer Case Outer Drive Bearing Preload	-	MD723603	-	0.0563​	-	1.43
Transfer Case Outer Drive Bearing Preload	-	MD723604	-	0.0575​	-	1.46
Transfer Case Outer Drive Bearing Preload	-	MD723605	-	0.0587​	-	1.49
Transfer Case Outer Drive Bearing Preload	-	MD723606	-	0.0598​	-	1.52
Transfer Case Outer Drive Bearing Preload	-	MD723607	-	0.0610​	-	1.55
Transfer Case Outer Drive Bearing Preload	-	MD723608	-	0.0622​	-	1.58
Transfer Case Outer Drive Bearing Preload	-	MD723609	-	0.0634​	-	1.61
Transfer Case Outer Drive Bearing Preload	-	MD726170	-	0.0646​	-	1.64
Transfer Case Outer Drive Bearing Preload	-	MD726171	-	0.0657​	-	1.67
Transfer Case Outer Drive Bearing Preload	-	MD756760	-	0.0669​	-	1.70
Transfer Case Outer Drive Bearing Preload	-	MD756761	-	0.0681​	-	1.73
Transfer Case Outer Drive Bearing Preload	-	MD756762	-	0.0693​	-	1.76
Transfer Case Outer Drive Bearing Preload	-	MD756763	-	0.0705​	-	1.79
Transfer Case Outer Drive Bearing Preload	-	MD756764	-	0.0717​	-	1.82
Part Description		Part #		ID Number		Thickness (mm)
	-		-	SAE	-	MM
Transfer Case Pinion Shaft Shim Preload	-	MD726172	-	0.0469​	-	1.19
Transfer Case Pinion Shaft Shim Preload	-	MD722081	-	0.0480​	-	1.22
Transfer Case Pinion Shaft Shim Preload	-	MD722082	-	0.0492​	-	1.25
Transfer Case Pinion Shaft Shim Preload	-	MD722083	-	0.0504​	-	1.28
Transfer Case Pinion Shaft Shim Preload	-	MD722084	-	0.0516​	-	1.31
Transfer Case Pinion Shaft Shim Preload	-	MD722085	-	0.0528​	-	1.34
Transfer Case Pinion Shaft Shim Preload	-	MD722086	-	0.0539​	-	1.37
Transfer Case Pinion Shaft Shim Preload	-	MD722087	-	0.0551​	-	1.40
Transfer Case Pinion Shaft Shim Preload	-	MD722088	-	0.0563​	-	1.43
Transfer Case Pinion Shaft Shim Preload	-	MD722089	-	0.0575​	-	1.46
Transfer Case Pinion Shaft Shim Preload	-	MD722090	-	0.0587​	-	1.49
Transfer Case Pinion Shaft Shim Preload	-	MD722091	-	0.0598​	-	1.52
Transfer Case Pinion Shaft Shim Preload	-	MD722092	-	0.0610​	-	1.55
Transfer Case Pinion Shaft Shim Preload	-	MD722093	-	0.0622​	-	1.58
Transfer Case Pinion Shaft Shim Preload	-	MD722094	-	0.0634​	-	1.61
Transfer Case Pinion Shaft Shim Preload	-	MD722095	-	0.0646​	-	1.64
Transfer Case Pinion Shaft Shim Preload	-	MD722096	-	0.0657​	-	1.67
Transfer Case Pinion Shaft Shim Preload	-	MD722097	-	0.0669​	-	1.70
Transfer Case Pinion Shaft Shim Preload	-	MD722098	-	0.0681​	-	1.73
Transfer Case Pinion Shaft Shim Preload	-	MD722099	-	0.0693​	-	1.76
Transfer Case Pinion Shaft Shim Preload	-	MD722100	-	0.0705​	-	1.79
Transfer Case Pinion Shaft Shim Preload	-	MD722101	-	0.0717​	-	1.82
Transfer Case Pinion Shaft Shim Preload	-	MD722102	-	0.0728​	-	1.85
Transfer Case Pinion Shaft Shim Preload	-	MD722103	-	0.0740​	-	1.88
Transfer Case Pinion Shaft Shim Preload	-	MD722104	-	0.0752​	-	1.91
Transfer Case Pinion Shaft Shim Preload	-	MD722105	-	0.0764​	-	1.94
Part Description		Part #		ID Number		Thickness (mm)
	-		-	SAE	-	MM
Transfer Case Mid Housing Spacer Plate	-	MD720353	-	0.0051​	-	0.13​
Transfer Case Mid Housing Spacer Plate	-	MD720354	-	0.0063​	-	0.16​
Transfer Case Mid Housing Spacer Plate	-	MD720355	-	0.0075​	-	0.19​
Transfer Case Mid Housing Spacer Plate	-	MD720356	-	0.0087​	-	0.22​
Transfer Case Mid Housing Spacer Plate	-	MD720357	-	0.0098​	-	0.25​
Transfer Case Mid Housing Spacer Plate	-	MD720358	-	0.0110​	-	0.28​
Transfer Case Mid Housing Spacer Plate	-	MD720359	-	0.0122​	-	0.31​
Transfer Case Mid Housing Spacer Plate	-	MD720360	-	0.0134​	-	0.34​
Transfer Case Mid Housing Spacer Plate	-	MD720361	-	0.0146​	-	0.37​
Transfer Case Mid Housing Spacer Plate	-	MD720362	-	0.0157​	-	0.4​
Transfer Case Mid Housing Spacer Plate	-	MD720363	-	0.0169​	-	0.43​
Transfer Case Mid Housing Spacer Plate	-	MD720364	-	0.0181​	-	0.46​
Transfer Case Mid Housing Spacer Plate	-	MD720365	-	0.0193​	-	0.49​
Transfer Case Mid Housing Spacer Plate	-	MD720366	-	0.0205​	-	0.52​

 

[1990TSIAWDTALON]

AWESOME information!
Thanks Tim!

 

[all black 4G63]

Coming over from the other thread I was pulled from....

What does the contact pattern look like in both directions? What thickness inner backlash shim is being used for 0.0031" BL? What is the thickness of the side cover shim? With the bolts torqued you are saying it is binding, so, loosen the side cover bolts and see how it changes in feel by slowly hand tightening them, is it binding because of excessive bearing preload, or is it binding because the gearset is not set up properly for pinion height or pinion preload?

If we are determining that it is side cover bearing preload being set too high, remove the side cover, remove the bearing race and shim, install some 3/32" diameter solder pieces evenly spaced in the cover with some petroleum jelly, then reinstall the bearing race, and then reinstall the side cover and bolts tightening them evenly to 29 ft/lb. Let sit in room temp (like 68*-72* type room temp, not super cold as that will affect numbers). Now, turn the drive gear and see how it feels, this would be a zero preload value. If it is still binding you likely have a pinion height issue, but still confirm. Simply remove the front housing from the mid housing (measure the mid housing spacer plate shim and be sure to reinstall a good mid housing o-ring), then do the turning feel again. If it is nice and easy, then pull the side cover off, remove the bearing race and measure the solder thickness.

Shim list below -

Part Description		Part #		ID Number		Thickness (mm)
Transfer Case Inner Drive Backlash	-	MD746510	-	0.0421​	-	1.07
Transfer Case Inner Drive Backlash	-	MD746511	-	0.0433​	-	1.10
Transfer Case Inner Drive Backlash	-	MD756755	-	0.0445​	-	1.13
Transfer Case Inner Drive Backlash	-	MD756756	-	0.0457​	-	1.16
Transfer Case Inner Drive Backlash	-	MD756757	-	0.0469​	-	1.19
Transfer Case Inner Drive Backlash	-	MD756758	-	0.0480​	-	1.22
Transfer Case Inner Drive Backlash	-	MD756759	-	0.0492​	-	1.25
Transfer Case Inner Drive Backlash	-	MD726167	-	0.0504​	-	1.28
Transfer Case Inner Drive Backlash	-	MD726168	-	0.0516​	-	1.31
Transfer Case Inner Drive Backlash	-	MD726169	-	0.0528​	-	1.34
Transfer Case Inner Drive Backlash	-	MD724326	-	0.0539​	-	1.37
Transfer Case Inner Drive Backlash	-	MD724327	-	0.0551​	-	1.40
Transfer Case Inner Drive Backlash	-	MD724328	-	0.0563​	-	1.43
Transfer Case Inner Drive Backlash	-	MD724329	-	0.0575​	-	1.46
Transfer Case Inner Drive Backlash	-	MD724330	-	0.0587​	-	1.49
Transfer Case Inner Drive Backlash	-	MD724331	-	0.0598​	-	1.52
Transfer Case Inner Drive Backlash	-	MD724332	-	0.0610​	-	1.55
Transfer Case Inner Drive Backlash	-	MD724333	-	0.0622​	-	1.58
Transfer Case Inner Drive Backlash	-	MD724334	-	0.0634​	-	1.61
Transfer Case Inner Drive Backlash	-	MD724335	-	0.0646​	-	1.64
Transfer Case Inner Drive Backlash	-	MD724336	-	0.0657​	-	1.67
Transfer Case Inner Drive Backlash	-	MD724337	-	0.0669​	-	1.70
Transfer Case Inner Drive Backlash	-	MD724338	-	0.0681​	-	1.73
Transfer Case Inner Drive Backlash	-	MD724339	-	0.0693​	-	1.76
Transfer Case Inner Drive Backlash	-	MD724340	-	0.0705​	-	1.79
Transfer Case Inner Drive Backlash	-	MD724341	-	0.0717​	-	1.82
Transfer Case Inner Drive Backlash	-	MD724342	-	0.0728​	-	1.85
Transfer Case Inner Drive Backlash	-	MD724343	-	0.0740​	-	1.88
Transfer Case Inner Drive Backlash	-	MD724344	-	0.0752​	-	1.91
Part Description		Part #		ID Number		Thickness (mm)
	-		-	SAE	-	MM
Transfer Case Outer Drive Bearing Preload	-	MN168245	-	0.0386​	-	0.98
Transfer Case Outer Drive Bearing Preload	-	MN168246	-	0.0421​	-	1.07
Transfer Case Outer Drive Bearing Preload	-	MN168247	-	0.0457​	-	1.16
Transfer Case Outer Drive Bearing Preload	-	MN168248	-	0.0492​	-	1.25
Transfer Case Outer Drive Bearing Preload	-	MD723600	-	0.0528​	-	1.34
Transfer Case Outer Drive Bearing Preload	-	MD723601	-	0.0539​	-	1.37
Transfer Case Outer Drive Bearing Preload	-	MD723602	-	0.0551​	-	1.40
Transfer Case Outer Drive Bearing Preload	-	MD723603	-	0.0563​	-	1.43
Transfer Case Outer Drive Bearing Preload	-	MD723604	-	0.0575​	-	1.46
Transfer Case Outer Drive Bearing Preload	-	MD723605	-	0.0587​	-	1.49
Transfer Case Outer Drive Bearing Preload	-	MD723606	-	0.0598​	-	1.52
Transfer Case Outer Drive Bearing Preload	-	MD723607	-	0.0610​	-	1.55
Transfer Case Outer Drive Bearing Preload	-	MD723608	-	0.0622​	-	1.58
Transfer Case Outer Drive Bearing Preload	-	MD723609	-	0.0634​	-	1.61
Transfer Case Outer Drive Bearing Preload	-	MD726170	-	0.0646​	-	1.64
Transfer Case Outer Drive Bearing Preload	-	MD726171	-	0.0657​	-	1.67
Transfer Case Outer Drive Bearing Preload	-	MD756760	-	0.0669​	-	1.70
Transfer Case Outer Drive Bearing Preload	-	MD756761	-	0.0681​	-	1.73
Transfer Case Outer Drive Bearing Preload	-	MD756762	-	0.0693​	-	1.76
Transfer Case Outer Drive Bearing Preload	-	MD756763	-	0.0705​	-	1.79
Transfer Case Outer Drive Bearing Preload	-	MD756764	-	0.0717​	-	1.82
Part Description		Part #		ID Number		Thickness (mm)
	-		-	SAE	-	MM
Transfer Case Pinion Shaft Shim Preload	-	MD726172	-	0.0469​	-	1.19
Transfer Case Pinion Shaft Shim Preload	-	MD722081	-	0.0480​	-	1.22
Transfer Case Pinion Shaft Shim Preload	-	MD722082	-	0.0492​	-	1.25
Transfer Case Pinion Shaft Shim Preload	-	MD722083	-	0.0504​	-	1.28
Transfer Case Pinion Shaft Shim Preload	-	MD722084	-	0.0516​	-	1.31
Transfer Case Pinion Shaft Shim Preload	-	MD722085	-	0.0528​	-	1.34
Transfer Case Pinion Shaft Shim Preload	-	MD722086	-	0.0539​	-	1.37
Transfer Case Pinion Shaft Shim Preload	-	MD722087	-	0.0551​	-	1.40
Transfer Case Pinion Shaft Shim Preload	-	MD722088	-	0.0563​	-	1.43
Transfer Case Pinion Shaft Shim Preload	-	MD722089	-	0.0575​	-	1.46
Transfer Case Pinion Shaft Shim Preload	-	MD722090	-	0.0587​	-	1.49
Transfer Case Pinion Shaft Shim Preload	-	MD722091	-	0.0598​	-	1.52
Transfer Case Pinion Shaft Shim Preload	-	MD722092	-	0.0610​	-	1.55
Transfer Case Pinion Shaft Shim Preload	-	MD722093	-	0.0622​	-	1.58
Transfer Case Pinion Shaft Shim Preload	-	MD722094	-	0.0634​	-	1.61
Transfer Case Pinion Shaft Shim Preload	-	MD722095	-	0.0646​	-	1.64
Transfer Case Pinion Shaft Shim Preload	-	MD722096	-	0.0657​	-	1.67
Transfer Case Pinion Shaft Shim Preload	-	MD722097	-	0.0669​	-	1.70
Transfer Case Pinion Shaft Shim Preload	-	MD722098	-	0.0681​	-	1.73
Transfer Case Pinion Shaft Shim Preload	-	MD722099	-	0.0693​	-	1.76
Transfer Case Pinion Shaft Shim Preload	-	MD722100	-	0.0705​	-	1.79
Transfer Case Pinion Shaft Shim Preload	-	MD722101	-	0.0717​	-	1.82
Transfer Case Pinion Shaft Shim Preload	-	MD722102	-	0.0728​	-	1.85
Transfer Case Pinion Shaft Shim Preload	-	MD722103	-	0.0740​	-	1.88
Transfer Case Pinion Shaft Shim Preload	-	MD722104	-	0.0752​	-	1.91
Transfer Case Pinion Shaft Shim Preload	-	MD722105	-	0.0764​	-	1.94
Part Description		Part #		ID Number		Thickness (mm)
	-		-	SAE	-	MM
Transfer Case Mid Housing Spacer Plate	-	MD720353	-	0.0051​	-	0.13​
Transfer Case Mid Housing Spacer Plate	-	MD720354	-	0.0063​	-	0.16​
Transfer Case Mid Housing Spacer Plate	-	MD720355	-	0.0075​	-	0.19​
Transfer Case Mid Housing Spacer Plate	-	MD720356	-	0.0087​	-	0.22​
Transfer Case Mid Housing Spacer Plate	-	MD720357	-	0.0098​	-	0.25​
Transfer Case Mid Housing Spacer Plate	-	MD720358	-	0.0110​	-	0.28​
Transfer Case Mid Housing Spacer Plate	-	MD720359	-	0.0122​	-	0.31​
Transfer Case Mid Housing Spacer Plate	-	MD720360	-	0.0134​	-	0.34​
Transfer Case Mid Housing Spacer Plate	-	MD720361	-	0.0146​	-	0.37​
Transfer Case Mid Housing Spacer Plate	-	MD720362	-	0.0157​	-	0.4​
Transfer Case Mid Housing Spacer Plate	-	MD720363	-	0.0169​	-	0.43​
Transfer Case Mid Housing Spacer Plate	-	MD720364	-	0.0181​	-	0.46​
Transfer Case Mid Housing Spacer Plate	-	MD720365	-	0.0193​	-	0.49​
Transfer Case Mid Housing Spacer Plate	-	MD720366	-	0.0205​	-	0.52​

Hi TWICKS69 thank you very mich for the info I will answer all your questions as detailed as I can,

What does the contact pattern look like in both directions? I will update shortly with a video and photos of the contact pattern.

What thickness inner backlash shim is being used for 0.0031" BL? Honestly the service manual was not very clear in to which shim is used to address backlash so changed the mid housing shim to a .28 MD720358 to achieve .003" if I used .31 MD720359 or .34 MD720360 the backlash was over .010"

What is the thickness of the side cover shim?1.52 MD723606 I used this with a drive gear pinion shim of 1.49 MD724330 mainly to obtain my turning torque of 1.25 ft. lbs.

With the bolts torqued you are saying it is binding, so, loosen the side cover bolts and see how it changes in feel by slowly hand tightening them...Yes, with the side cover backed off or loosened the input turning torque is considerably less and easy to turn.

is it binding because of excessive bearing preload, or is it binding because the gearset is not set up properly for pinion height or pinion preload? I am not 100% sure if this thing is actually binding..it may just be a little stiff and jumpy due to a freesh input drive gear bearing and lack of oil and wear? This is the part I am not sure of. I will try to post a good video of me turning it, but you need to use a output shaft to turn it.

Now, turn the drive gear and see how it feels, this would be a zero preload value. If it is still binding you likely have a pinion height issue, but still confirm. Before using the 1.52 I had a 1.49 MD723605 and the turning torque was too loose.

You must be logged in to view this image or video.

I will report back with photos and videos.

Thank you again for your time and info
Anthony

 

[twicks69]

0.001" difference in preload wouldn't make it go from binding to loose. I think you are going to need to dye test the gearset and see where the pattern is contacting in both directions.

Put the 0.012" thick mid housing spacer in, and then adjust the backlash shim to a thinner value, like MD724327 or MD724328, then adjust the thickness of the side cover for preload last. Start with a thicker shim installed in the side cover so you can confirm you have preload on the input sleeve then assemble the front housing to mid housing and torque mid housing bolts, then install input sleeve carefully so you don't damage the input seal, then install side cover and hand tighten fasteners down. Rotate it a few times, then measure backlash then if the preload on the side cover is too much to turn smoothly, just slightly loosen the side cover bolts and start doing revolutions to see how the feel changes, then measure backlash again and then work on pattern.

Once you have pattern and backlash done, do the solder method in the side cover to get a zero value, find the shim for 0.001-0.002" preload, then test with 0.003-0.004" preload to see how it feels.

Typically I set up the OEM gearset for 0.0040-0.0060" backlash, 0.002-0.003" side cover preload, 0.002-0.003" pinion bearing preload with shaft nut torqued.

 

[all black 4G63]

Hello Tim,

Thanks for the help. I thought I would post photos and videos of the contact pattern and backlash before going forward with total disassembly and trying to find shims that are not available as I only have 2 more mid housing shims at .31 and .34 and one side cover shim at 1.49

In the first video I am turning the case with an input shaft by hand and I realize that it is not in fact binding what is it happening is teeth chatter is occuring causing a noise due to my .007" backlash. Is this really an issue??? or is this just due to lack of of oil a load from the rest of the drivetrain?

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In this video I am showing the backlash measurement of .007" is this really that bad? i know the service info spec is .003-.005"

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And I have attached photos of my contact pattern.

Thank you again for any insight you can provide from this info.

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[all black 4G63]

From the contact pattern it seems as if i need a slightly larger mid housing spacer, does this sound correct?

I am basing it off of the driven bevel gear is too high and coast side too low???

 

[all black 4G63]

OK Tim I took your advice and reduced the pinion input bearing shim and the side cover shim to 1.49 on both side and the turning torque freed up. I also used the .012" mid housing spacer and the contact pattern was good and backlash at .004-.005"

Thank you very much for your input!

 

[twicks69]

What i do for setting up is use a tub of petroleum jelly mixed with 75w140NS gear oil so that i can lube the bearings and races and put a little on the gear teeth with my set up dye. It won't hurt it hand spinning it dry but it will be noisier. Again though, you will hear pinion height issues easier with them dry; it will be obvious.

Also, I find it easier to just put the output shaft in soft jaws on a bench vise, then install front housing onto the mid housing and hand-spin the entire assembly both directions. Much faster than a transmission output shaft in it and having a worn input sleeve or output shaft splines affecting the readings.

 

[all black 4G63]

Good idea I will try that.

Is it ok to leave the gear lash compound or contact pattern paint on the gears or should it be cleaned off before use?

 

[all black 4G63]

I also wanted to ask what you recommend for fluid in t trans and transfer? It’s just a street car

75-85 both or 75-90 both or one another?
Thanks

 

[twicks69]

I normally use machinist dye with petroleum jelly mixed with 75w140NS gear oil which dissolves fine with gear oil. With that paint, I would probably clean off as much as you can and run it.

If its stock power, well below 400hp, sure that is fine. Mitsu used a 85w90 multi-gear dino oil from Eneos when manufactured.

For higher power levels, I prefer redline 75w140NS (no slip version) in the transmission , and you can get away with a 75w140 in the tcase. If you choose to use heavyweight shockproof in the transfer case, please note that the paraffin content settles out over time and it is designed for very regular fluid changes.

 

[ty1975]

Cool thread, lots of good info. I have been in the process of re-setting mine up for the last three or so months. You’ll have to let us know how it drives and sounds. Mine had a real bad fear noise on acceleration because it was set up with no backlash.. got it on .004 now. Just gotta find time to put it on the car again. Good work on yours.

 

[all black 4G63]

Hey ty1975

my T-Case is working great. with a .004-.005 backlash and decent contact pattern everything is working out. I even dropped the fluid around 100 miles to check for anything and it was all good.

Just get your contact pattern and backlash as good as you can get it and you will be ok. Also make sure you turning torque is good..i.e. i was able to rotate my input shaft by hand.