Atv Overdrive Installation Question

I am installing a new to me, looks brand new, ATV overdrive unit.

Most of my questions were answered here . This is a great video by "metal shaper".

In the instructions Herm states, "The top of the assembly should be 0.67~0.68 inches past the gasket surface of the transfer case". I was confused by this and there is no diagram, so in the video Metalshaper shows that its from the Synchronizer cone. He made it clear..

Anyway, my measurement is .6835. The question is, will that .0035 make a difference and cause the OD to pop out of gear or other issues? The unit is torqued to 115lbs or so, started at 100 and had to put a little more on to make sure the lock washer and snap ring were properly installed... and fit kind of loose..

Thanks guys!

 

If it was me, I would probably pull the planetary assembly back off and make sure everything is clean and free of any burrs, dings, etc. Reassemble and check again. Sometimes just doing it again, getting it on different splines or something is all it takes. If it measures the same after doing it twice, I would just run it and see how it goes. My gut tells me there is likely a bit of leeway in the tolerance range.

Edit: Meant to add that I think what is at risk there is the clearance/free play of the synchro ring. Your stick-out being a bit on the high side would decrease that clearance.

 

I think it will be fine as is. There is a bigger problem if it is under that minimum. I suspect there is WAY more variation in the gasket thickness than .0035".

 

I read that there may be some variances in Herms manufacturing of these thrust bearing retainers. I took mine apart, cleaned it out and made sure the socket head screws were tight and no burrs in it. Herm has apparently told others that adapter kits can sometimes mess with the tolerances he sets out, but run it if it works. There seems to be some negativity about all this.

I don't have the right gasket for this, as I bought it secondhand. I will need to either cut my own gasket or, more likely, cut the one I have in my kit to fit. ...So, I can fine tune the gasket thickness to create a shim... Or make my own .003 shim if this isn't correct? When I shove this thing together, I will see how it works and adjust accordingly.. Just need to put it back together after I get the Howell harness and 4.3 reprogrammed computer..

Thanks guys!

 

What does Herm say?
I bet he even has the correct gasket.