Transmission Transfer Case

So I got one of Herm's conversions cause my T86 was shot. Mounted the new transmission with the transfer case and installed it (a three week process, but that's another story). Next day found a puddle of gear oil the size of a dinner plate underneath it. OK...now what did I do wrong, pulled it and took it apart. Got to looking at it, I'd obviously missed this the first time around, and saw an issue. The retainer plate on the two shafts protruding from the rear of the case obviously won't allow the transfer case to mate flush with the back of the transmission.



What's the fix for this, sealant?

Tom

 

The transmission reverse and countershaft lock plate must fit into the transfer case pocket !
Simply re-align the lock plate as is needed.
The dog ears of the lock plate should be on top.

 

You talking about the retaining plate the holds the counter shaft and/or revserse idler shaft in place?
If you might need to trim that plate to clear the adapter.

 

Yes, I have seen more than one new lock plate interferring with the fit of the transfer case, both on a T14 and a T90.
What you need to do may be more than one trial fitting without the gasket. Look for a shiny mark on the lock plate and grind or file it as needed until the transfer case fits with no gap to the back of the transmission. This is all work best done on the bench instead of underneath the Jeep.

Don

 

I had the same problem with the one I got from him...The one he put in mine was square...trimmed it up & it mated up.

 

Yeah...thanks for telling me you had the same issue. I just ended up trimming the retainer plate down to let the lip seat flush.



Clearly that retainer plate won't let the lip of the xfer case mate flush



Has anyone brought this to Herm's attention?
Think I'll forward these pictures to him.

Tom

 

I let him know...mine looked as though it had been fabricated "in shop" with no attention to detail. The top hat he sent with mine also needed rebuilding.

 

Looking at the top picture I wonder if the retainer should have been inserted from the bottom side?

 

:iagree:

 

The original shaft lock plate has "ears" to hold it from dropping down too far.
Those "ears" mandated that the lock plate was always inserted from the top side.

Without ears it makes no difference.
The plate may be installed from top or bottom so long as the shafts are used to "pinch" the plate into desired position.
The lock plate will always cover a portion of the rear bearing retainer.

 

What Oldtime said. The problem is the lock plates supplied in many of the rebuild kits are not correct for the T-90's and T-86's. for this reason I try and reuse original lock plates or I have to trim down the new ones. This is very easy to miss even for an experienced builder.

 

Well since we're having this discussion I thought I'd mention that I did send Herm those pictures. I also thought I'd show you guys whats going with my project. I decided to try one of these because a few years ago my oldest son and I did this



Ground up resto, and after that one I thought if would be a kick to do a 60's model with the Dauntless. Looked around and came up with this





Went and got it last winter on the morning after a -40 night and the thing wouldn't move. After I drained the transfer case my suspicions were confirmed. That's what came out.



Got it in the garage early last spring.





All in all the transmission has been the toughest nut to crack. This gear is one of the few parts for that T86 that can't be had for love or money



So between that, issue's with the pilot bushing, the case leaking like it had a hole in it after assembly, it's been challenging. Here is a shot of the tranny on one of it's multiple installations



But through it all we have "endeavored to persevere" and this is where it sits today





Pretty much everything is prepped and painted, just waiting on a few key parts and this baby should start to come together.

And just to add insult to injury, my son wanted something to drive around base so we found him this



So after all the hours I've spent restoring and rebuilding these things, right now he's the only one in the family that has a running jeep!!

Tom

And if anyone can tell me how to re-size these photo's I'd be forever in your debt.

 

I had the same assembly challenge, I ground away enough of the t-case to just clear the retainer.