Transfer Case Gear

Rebuilding the Dana 18 and found a bad spot on the sliding clutch gear. The corners of the gear are slightly rounded off and a chip out of one tooth would you guys run it or should I loo k for a new used one

 

I would look for another one . front output

 

Looks like someone had a habit of shifting on the fly. I would look for another but try a stone on it anyway.

 

i can say i am likely guilty for a similar effect on our t-case

 

Front output shaft. Replace it. It will continue to wear and down the road potentially cause the front to jump out of gear under load. I’d take a close look at the front output clutch as well. Most likely it is worn in a similar manner.

 

Is the entire damage limited to the three gears shown? Sliding gear good? How much do you use your front axle?
If the damage is limited to the three teeth, everything else is good, and you rarely use the front axle, then I wouldn't hesitate to take a file or stone to the rough edges and smooth them out in order to prevent further flaking and chipping.
If you can afford it, need the peace of mind, or use your four wheel drive constantly or heavily (plowing, ranch rig, etc...) then replace it.

 

You have it all apart.
Now is the time to replace it.
Not later....
Fix it once, fix it right.

 

I don't really enjoy pulling transfercases all that much. I too would replace that. If you do get additional flaking from using your existing output, those chips can cause more damage.

 

Might DeBella have a NOS replacement? Looks like yes - Willys Civilian Jeep CJ3B CJ5 - Transfer Case - Peter DeBella Jeep Parts www.debellajeepparts.com - 807892, only $40. I'd replace the mating gear too.

 

Richard at R&P Early Jeep Parts has boxes of used ones. 503-557-8911. I’m sure John at Border Parts and many others do to.

 

Thank you I will give him a call.