so i ordered my t-case gears finally from RR along with upgraded mounting bushings. is there any thing else i may want to install while i am working in that area or does anyone one have any tips from things they did or ran into while doing the install

thanks and looking forward to all advice

forgot to add that this is for a 88 sammy with yj springs running 33s

Pop out the old T-case breather and tap it for a fitting that will accept a breather line.
Its a piece of cake to do while its all apart, and its just a little bit extra piece of mind.  Not having to worry about getting some water in there.

Amilla

Make sure you grind out both sides of the T-Case on the inside to accept the larger gears.  When I put together my setup the instructions only mentioned grinding out the one side, which worked great until I bolted it all together. 

did you also, order the mega-mount t-case mount kit?
It works pretty well. really helps hold the t-case from twisting.

no i just ordered the upgraded bushings for now then in about a month going to get the mounts. Im still running the 1.3 do you think i am going to see any twisting within the next month

When you put the upgraded bushings in replace the washers with some larger flat washers.  The ones they give you are to small and tend to eat into the bushings and cause them to fail.

thanks that seems like a small and cheap problem you would think they would fix. Also wanted to know how weak the stock front output shafts are after gearing the the t-case. i didnt order one and have been wondering. have any of you ever had problems with it.

yes throw the bushings in the garbage and the bolts and use shorter bolts with no rubber (i spent all day saturday out on maze trail in st george on my back fixing glens "lifetime bushings") and yes you will bend your mounts my mighty kong is holding up but the smaller mount i plated the top with 1/4 inch steel is now bent oh and i have 5 torn bushings you can have

what engine do you have, and how long did it last until you started having problems

When you put the upgraded bushings in replace the washers with some larger flat washers.  The ones they give you are to small and tend to eat into the bushings and cause them to fail.

I never had a problem with my set up from RRO...
I think the washer bushing problem occurs from over-tightening and squishing the bushings...   

There are 2 school of thoughts that I have heard...
1: You want the t-case to shift and move
2: Bolt that M|removethispart|@#%$  F&%$% down and allow no movement

I have heard good things about the brass bushing set.

I like having the bushings to absorb most of the shock, and I don't like loose bolts holding things together.  One of the main problems with the RR bushings are that they have that lip in them for some reason, and that seems to be where some of the tears start.

Went out wheeling with a rig that had the aluminum bushings from Trail Tough on it.  Work great, but any drive line chatter is transmitted straight to the frame.  So if you have any u-joints that are worn a little you will certainly know about it. 

I can see over-tightening causing the problem though.

santa in the brown truck just delivered the gears, ill probably start digging into it tonight. hopefully i dont have to cry for help with this.

You got it! its a piece of cake!

Amilla

just a quik question for anyone who has done this before. I have everything apart and noticed on the large output shaft that the very tips of about 4 of the teeth just above the snap ring are chipped. from what i could see it doesnt look like it will affect anything. I know that Trail Gear has the heavy duty shaft is that something that i need