Outer Limits 4x4 Board

i've just purchased some 4.16 tcase gears. i have approached my mate (3rd yr apprentice mechanic) to fit the gears. he's never rebuilt a tcase before and is unsure how difficult it will be. i'm sure he'll be capable. what do you guys think?
cheers dan.

they are pretty straight forward
a 3 rd year apprentince should be able to do it no worries particularly with instructions if he cant he sould give up
between him his boss they should manage fine and its good practice for him

As long as this 3rd year apprentice isnt from a dealer that only does services....Im sure he will be capable... As long as he has the right tools, and your helping, 2minds are better then 1!

thats what i thought too. i know he's a good mechanic. i'll tell him they're pretty straight forward. cheers for the reply

does anyone know where i can get some decent instructions for a transfer rebuild? i thought some instructions would come with my gears but i didnt receive any

Have a look at this.

http://www.trail-gear.com/tech/zuk65gears/index.html

Here are the instructions for fitting 6.5's.

http://www.trail-gear.com/tech/zuk65gears/index.html

I used those instructions when I did a full rebuild and fitted my new 6.5's. From memory there is 1 or 2 bearings that they don't touch in those instructions, but you really cant go wrong - If you have a new part/bearing/shaft to go in you will find where it goes! It all makes sense when you have it all apart!

Cheers,

Pez

thanks very much everybody. i can't wait to test the gears out

The instructions for the 6.5 gears say you need to do some grinding. You shouldn't have to for the 4.16 set you said you are installing. Just check gear clearances before you do anything uneeded.