pulled out dad's t-case today and this is what we found.....






dont know what we did wrong quite yet but we are looking into it
it appears that the engagement cog and the low range gear didnt get along togeather and mashed each others face in
we didnt have any left over parts and it worked good for about 4 or 5 times and then just quit working, so we are kinda stumped as to what happened
this is what we are left with.... screwed up crawler gear and main shaft cog, everything close to it has heat markings, lots of hard work down the crapper :'(
 
damn, damn, damn, damn, damn (trying to be polite)

$650.00 paperweight (i've made some expensive ones in my day, but this one takes the cake)

if anyone has any ideas i'm listening
i'm going to get back to crying and reading the instructions (again and again and cry and read again)
jason

Don't want to state the obvious but did you have enough oil in there as that'll do it.

OUCH! Just curious, but what brand was that reduction? Any chance of getting it warrantied?

yes we had oil, duh
and itis t/t gears and we are going to talk to him monday
need to figure out what went wrong, first
jason

I'm familiar with gear mesh issues, but not gear reductions yet. Did the kit include all new gears or were some gears re-used from the previous case? If you re-used any worn gears and put brand new gears against them, I can easily see that causing the problem. If all the gears were new, I would tend to think that one of them had a slight defect, maybe a stress riser like a bubble if they were cast gears or a nick if they were machined...

What year was the case? Is it possible that it was a 89-91? Ive never seen that before.

Mike

Did the transfer cases differ year to year?

Just 2, early 89-91, and late 92- ??

Word has it the 4.24 T-case gears
don't fit the early T-case, But I don't
know, I have an 89' and didn't want
to try it

Wild

Sorry to hijack from the low range gear problem, but would a 89 t-case work fine in my 94 tracker as long as it has the normal gears?

I think the only difference in cases is internal ribbing. I beleive they are functionally the same and mount the same way...

Ok thanks. I'm trying to gather as much information on this conversion as I can before I get down to it.

years might be the problem, it was a 91 case that we put them in, but brent advertises them to fit a 91-98 sidekik or tracker. it is possible that the doner car that we got the t-case out of was a 90 regestered as a 91(sold early in 91)if so then oops
still dont know
jason

If you had the odd ball case you would of known. The regularly sold gears wont even line up in the odd ball 89 case. I did not have a clue what I was doing when I installed my 4:1 (the first time I had even taken a tcase apart) and it was obvious that I had the wrong gears. GRP had to ship me another set that would work in my 89 case. The other gears would not even come close to lineing up.

Zig

If you had the odd ball case you would of known. The regularly sold gears wont even line up in the odd ball 89 case. I did not have a clue what I was doing when I installed my 4:1 (the first time I had even taken a tcase apart) and it was obvious that I had the wrong gears. GRP had to ship me another set that would work in my 89 case. The other gears would not even come close to lineing up.

Zig

I almost got them installed in an 89 case when I realized that the case was not seatting all the way togather. It was a couple years ago but I thought it was only getting held up by about 1/3 inch or less.  The difference is the thickness of the 2 gears in the front of the case. If you put the thicker gears in a case set up for thin ones... Mabey... Just a guess.

Mike

I remember something not looking right and we noticed it before we ever got it back together. I think the low rang gear did not fit in properly so we pulled them out and compared them to the stockers side by side. That is when we decided to call GRP and see what was up But that has been a LOOOOONNNNGGGGG time ago

Zig