so all the gears are in an i have everything back together and I figure i will be crawling in no time. Wrong i cannot for the life of me get the nut on the rear output shaft (the biggest of the three) to start threading. anyone ever run into this . If worst case it is mushroomed at the end can i find a replacement shaft anywhere.

try switchin it with the others they go on their origanal spot best and make sure you have the flanges in the right spot the taller one is the rear if its for sure buggered on the shaft then grind a tappered edge to get past the bad spot 


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              /          \    like this

if that is one of the new shafts maybe it is messed up from the factory? or a different size? did you shim the front output shaft while you where in there and also put in a new counter shaft with new needle bearings I hope?

yah i did do the needle bearings and counter shaft but dont know anything about shimming the front output. I just bought the kit from Rocky Road.

UPDATE, rear output shaft nut not threading problem is fixed thanks for the advice.

They sell an updated front output but there a hundred bucks,most just pull it out and pull the bearing off and put a washer behind it and press it back on(.020 to like .030 thick) it moves the shaft father into the shift collar so it does not pop out of 4wd on a hard hill climb etc.

good to know, yah i knew about the front output shaft but didnt want to spend another hundred bucks on top of the 500 gear kit. I already have the t-case back in am i going to wreck anything if i dont shim the front output shaft

hard to say how hard you wheel and when it kicks out if your on a hill climb or not? it would just put all of the pulling power to the rear wheels and it depends on the hill and what not, I have the 6 to 1's in mine and it never popped out until I installed them and run it up a bumpy steep hill climb but I run mine up skider trails that most people can't walk up!

Mine used to pop out of gear all the time when I bounced it really hard against some rocks.  A new shifter sheet fixed that though. 

I didn't even want to have to worry about my my front output shaft, if you already put the 500 into it why not spend the extra 90 bucks to make it rock solid.

Amilla

When I got my gears they were like 675.00 from t.t. and then another 89.00 for the bearing kit plus shipping and I don't have a lot of money so 100.00 would of meant waiting a long time to get it going because I broke the 4 to 1's that were in there and I did not get a whole lot for warranty on them for being a life time warranty. and the shift sheets last for like twenty years or so and I'm on my second or third one (I think I put a new one in every time I have it appart.) and my kong mount has a couple of extera bump stops on the top of it to keep it from hitting the shifter by the boot to knock it out of gear so i'm good there also.

well i got the gears all in and went and tested it out and am more than happy with the difference. Some of the hills and terrain i never had a chance at hardly phase me now. I appreciate all the advice i think the mighty kong and the front output shaft are going to have to be ordered by the end of the week.