Outer Limits 4x4 Board

Hello Guys,

I need some technical advice from the gurus and those who have experience
installing the Ultra Low TC case gears for the 2.6L gen 1 pajero.

I have finally decided to install the gears but was stop by the problem of
the previous hole being smaller than the gears. The prebious gear which
has 22 teeth has no problem going into the hole but the new gear with
27 teeth won't fit.

here is a picture.



Here is the hole and the gear in the picture.



If I enlarge the hole so that the gear will fit then the bearing which is force
fitted into the hole will be loose





If I install the assembly from the bottom, I cant install the c clip lock.





My mechanic suggested that we ask a machine shop to enlarge the hole
then buy a bearing that has an enlarged outer diameter so that it would
still fit and has the same inner diameter.

Is this the way to do it, mates? Thank you very much in advance for your
advice.

mate, i dont recall the cases having to be modified to that extent!.

Are you sure you havent got gears meant for the larger transfer cases, ie the 3.5l & 2.8 TDI. They were a larger gearset.

Ian Sharpe wrote:mate, i dont recall the cases having to be modified to that extent!.
Are you sure you havent got gears meant for the larger transfer cases, ie the 3.5l & 2.8 TDI. They were a larger gearset.

Hello Ian, thank you very much for the reply. Yes Im very sure that I bought
the right one. Its for the 2.6L gen1 pajero. I have emailed marks4wd but I
don't have a reply yet so I will email them again.

And yes Ian, there is nothing in the instruction set that says I have to
bring it to the machine shop and replaced a bearing.

Actually the gear is just very slightly bigger than the hole. In fact i was
thinking of forcing it in and maybe slightly destroying some edges, but
it does'nt seem to be the right thing to do. Is it possible that there
are different versions of the same transfer case? And some holes
are slightly bigger than the others?

ok, if you dont have any luck with this you should contact Mark or Leigh Hardman in Melbourne, they actually make the gears. They are both very helpful & could probably even send you some instructions.

Also Frank Zanetti on this forum is pretty clued up on the gears too.

here is Hardmans contacts

385-393 Lower Dandenong Road
Dingley, VIC 3172
AUSTRALIA

info@hardmanbros.com.au
+61 3 9551 5566
+61 3 9551 8060

Thanks Ian,

I have sent them another email yesterday and hopefully
they will reply.

ANybody in the forum who has experience installing
the TC gears too? I would really appreciate if you can
share it here. Many thanks in advance.

Hello Mates,

Thank you very much for the leads. I have finally installed my TC gears
with the help of Marks4WD. I am now changing all the TC and transmission
oils with GL4 gears oils. I will try my rig this coming thursday and see
how it goes. Again many thanks to Ian.

Good news,

what did you do to get them to fit??

Ian Sharpe wrote:Good news,

what did you do to get them to fit??

Hello Ian,

There were 2 major things that has to be undone.
1. First I remove a post that was already installed
2. The gear was installed from the other side which make it possible
because the post above was uninstalled.

so basically wrong assembly sequence. Its hard to explain without
the pictures.

ok glad you got it in.

thay make a huge difference, believe me.