Cracked transfer case-?

JB weld may band aid the leak, temporarily but will not add enough support to the case to keep the gears in alignment. It's not just about the case at this point. With the misalignment you have plus the clearance changes you WILL wipe out the bearings and most likely the gears and shafts. Fix it right now or plan on spending a LOT more in the near future to get it up and running. Right now you can probably save most of the parts like gears and shafts. Keep running it and most likely not. These parts in good used shape are not getting easier or cheaper to find.

 

Google " dana 18 transfer case girdle" Tri County Gear in LA used to make one for the D-18 for the pan rail.................But I agree with Nick 100% .............lick your wounds and save what you have left. If you want a stronger case find a Dana 20 and put all of your good 18 parts in it..........Novak sells them for about $200 bucks.

 

Yup. Not sure if Jason Bunch still is but they made two versions. One that wen on the pan rail and one that went on the pan rail and extended up to bolt onto the pto port as well.
It's meant to strengthen an existing good case though, not to band aid a broken case.
Terry, do you know if Tri County gear is still making them? Iirc it was kind of Jason's baby.

 

Nickmil,

Last time I had my CJ at Tricounty Gear a couple years ago, Jason pitched the girdle to me as a suggested component for more radical wheeling. I'm gonna to assume he'll still make them, but they aren't listed on the new website.

Wouldn't hurt to call, I know he's still in every day there.

 

Once again thanks for the advice and as it keeps coming in it's become more and more clear that it should just be replaced. Tarry99 mentioned using a Dana 20 housing which I've been told is a little more heavy duty. Are all the Dana 18 and Dana 20 housings interchangable? Does it matter if my t case is a single stick?

 

Thanks Don, That is good news, I wanted to rebuild an extra TC so I could replace the one in my TP in one day. Then rebuild the original and have it on a shelf. I will give it a try. I was going to do that this winter, but when I saw they were different I was kind of Bummed out. Thanks Again, you guys are a great help.

 

Don I just read your next post, I don't know about the small index and the large index case, so I will wait until I know the difference. The single stick case I have has only 27k miles on it and I don't know how many miles are on the twin stick case. All me parts are from three jeeps, two 64's and a 66 V-6. Thanks again Rick

 

Rick,
The large and small index refers to the size of the opening in the front of the transfer case where it attaches to the transmission. The back of the transmission will have a round stepped bushing around the output bearing that is 4 inches OD for the large index Tcase, and the small index case uses a somewhat smaller diameter bushing (I don't recall the exact size, somewhere around 3 1/2 inches). Measure the opening diameter of the Tcase and you'll see what I mean. Most of the cases with the single cast protrusion on the back for the shifter rod are small index cases and won't fit the back of the V6 transmissions whether T86 or T14.

These Tcases are easy to rebuild with basic hand tools. The only exception is the dial indicator you need to set the rear bearing end play. Buy one from Harbor Freight for around $35 including the magnetic stand, it will be adequate for that job. Do an internet search for Rick Stiver's guide (I think that is his name), it shows you everything you need to know.

Nick and the other guys are right, that case is history and will make most all its internal parts history if you try to continue running it.

Don

 

Fix it once.
Fix it right.
Sleep good at night.

 

All right, so this is where I stand. After Posimoto pointed out I may have some chipped teeth, I have it a better look and he was right. Actually it was ALOT worse.






so with this and the cracked t-case housing, I've just decided to replace the whole thing. Ordered one today so hopefully the jeep should be back on the road real soon. Just a little apprehensive to put a new one on without really knowing what caused it in the first place. Hope it doesn't happen again.

Thank You for all the advice and input on all angles of this issue. I hope seine else maybe able to benefit from this thread.
RJ

 

Don, I understand now, The single stick I have does have the bigger spacer, the twin stick does not. I don't know about the single stick that is in my Jeep now, it is the one that came in the 1964 TP from the factory, I think. It makes noise when I decelerate from high speed, 55-60 mph, so I push in the clutch and use the brakes to slow down. I put 1966, 3:73, V6 axels in it, I can cruise at 55, without any strain on the motor. It don't like long hills though. I put the gears from a column shift in a floor shift trans, I think that second gear is a little lower than a floor shift, so it doesn't have any trouble getting up to speed on the road. Thanks again. Rick

 

Looks to me like the broken teeth is what broke RJ's transfer case, wedging it apart.

 

is that rust where the break on the gear teeth has occurred?

 

You know Rick I'm not sure if the cracked teeth is what caused the t case to crack since the broken teeth was older damage. (Had no broken teeth, metal shavings in fluids when drained)
And no it's not rust, but oil.

Thanks

 

Just a thought RJ. It is odd to me that two gears that don't slide would break and someone took the pieces out. Those are constant mesh, it seems like something had to get in there to break off teeth on those gears. But what do I know, I am a 70 year old student myself.