Outer Limits 4x4 Board

I've just installed some 6.5:1 gearing in my t-case and it won't engage 4x4. The lever moves through all positions smoothly ie 2h, 4h, 4L. High and low range work but it won't allow drive to the front shaft. The lever moves correctly to engage 4x4 but the problem is that the ring that moves across to allow drive to the front isn't reaching the front shaft. I think there might be a problem with the front shaft part goin into the longer shaft. The reason I believe this is the problem is because I have the internals from a second case here too and when interchanging parts the other parts lead me to believe the bearing located in between these parts ( shown circled in yellow in pic) is what is stopping the other part goin in and therefore not allowing for it to lock into 4x4 because it can’t reach.

In the pic I’ve circled the part in red which is supposed to go into the hole that is circled in yellow. And atm I’m thinking that, that is the problem. I’m gonna try and remove it and change in another bearing this week (I have a severe case of dermatitis on my hands so I can’t work on the car right now) but I’m after any other help or experiences people might have had with cases or any other advise.

Hopefully I can sort it out soon and start wheeling my POS! And hopefully this post makes some sense to others as it’s hard a bit difficult to explain

Cheers, Mark.

pic

was both the detent bearings put in?
i believe there is two of them in there.
cheers

nicbeer wrote:was both the detent bearings put in?
i believe there is two of them in there.
cheers

I'm not sure which bearings are the detent bearings but yes, I beleive all bearings are in there as i copied from the other internals and the instructions that came with the gearing. And i replaced in total 9 bearings i think it was...

I was talking to someone about this and they suggested maybe the main shaft was out of alignment, soemthing for me to consider I guess.

Mark.

I bet you have buggered the little pilot baring on the main shaft when you were pulling the gears off for the change.
The pilot baring is in where you have circled in yellow

Yep, this is exactly what I'm thinking too. Now I just had a quuick look at it and I don't know how to remove this bearing... can anyone help me here who's done it before?

And I compared the position of that bearign to the one I have on a spare shaft and it has been pushed in further into the shaft I think this must have happened when I tightened up the bolts on the fornt part of the case. Is there anythign else I should check that might have been forced out of alignment as well?

Mark.

P.S I hate transfer cases

Come on peoples, someone here must have changed this bearing before. I need to know how to remove this bearing. I've searched through suzuki manuals etc and there is no mention on how to remove it!!

Please someone tell me how to remove the bearing...

Mark.

I just took another pic close up of the bearing to better show it. This is just a close up of the same spot as in the other pic where i high lighted it in yellow.

I draw the outer casing and how the pins in the bearing sit as the photo wouldn't come out very clear.

Mark.

ya need sum waxy grease firm yet a bit plyable, a drift thats the same diameter as the hole its goin into. half fill the hole with waxy grease, proceed to hit drift with hammer, this forces the wax under the bearing and hopefully forces the outer of the bearing out. i learnt how to do this of a guy i saw trying to get a bronze spigot bearing out of a crankshaft, worked a treat.

bazooked wrote:ya need sum waxy grease firm yet a bit plyable, a drift thats the same diameter as the hole its goin into. half fill the hole with waxy grease, proceed to hit drift with hammer, this forces the wax under the bearing and hopefully forces the outer of the bearing out. i learnt how to do this of a guy i saw trying to get a bronze spigot bearing out of a crankshaft, worked a treat.

Hmmmm.... sounds interesting, had to read it twice to understand fully, hehe. Might give it a go on the weekend... any reccomdations on what kind of wax to use that has the right plyability? ( i dion't think "plyability" is the word but you know what I mean )

Mark.

i got wax mark

Have u got access to a puller,u might find a spigot bearing puller might work.When i did mine i had no choice except break the cage and get the needles out then i had a engraver with alot of attachments and grind the outer cage away...what a bitch it was as i tryed so hard not to grind any case harding away from the main shaft.Then i used a drift and hit the new bearing in...its been fine since.The attachment was like a small grinding stone in a small dowl kinda looking shape ,then i used some sand paper on another attachment.You can get these things in like Dicksmith i think.Hope this helps

try rubber grease, it works for me.