Transfer Case Drive Gear

When it loosens up it not only wears out the splines on the transmission output shaft and transfer case input gear but can come loose and bind up causing catastrophic damage to the transfer case. I’ve had to scrap literally hundreds of transmission output shafts and thousands of pounds of transfer case parts because of this. Torque on a part is not a “suggestion”, it’s a highly recommended process to keep problems from happening.

 

Yes, you are right!! Glad I did not have to do tons of them

 

Finally torqued to spec! I had to go all the way to 170 ft-lb to align the hole for the cotter pin. One down, a crapload more to go.

 

So.... did you put the tranny in two gears, hold the yoke, or do the rag trick?

 

I used the yoke holding tool I fabricated for the front axle rebuild. It took a little persuation to get to the torque in the spec and to have the castle nut in the right position to install the cotter pin. The whole transfer case/transmission was trying to tilt forward but a wooden block well placed, a couple of curse words and... done!

 

That's where you need a large friend to stand/sit on things. Nice work!