Dana 18 problem

Just as I was finishing everything to get the Jeep out of the garage to make room for the snow machines I discovered the source of the loud bang noise I heard last fall. My instincts were correct - it was the sound of teeth breaking off of a gear.

The noise sounded like someone hit something under the floor with a big sledge hammer.

It can be seen looking through the round opening at the back. Looks like 3 teeth broke off of the gear next to the input gear. Input gear looks ok.

I guess I always wanted to learn how to rebuild a tcase anyway. And do the twin stick (hello Nickmil) and maybe try getting the parking brake to work. I've been doing some research (Lynn - thanks for all the info you posted about your rebuild) and found this:
". . . now's the time to pull the inspection cover off of the bottom and give the intermediate gear a look-see. I waited too long and it cost me a new intermediate gear, output gear, and mainshaft gear.

Remember my reference to the clunk? It turned out to be broken pieces of my intermediate gear meshing with its friends! If you wait as long as I did, you will be rebuilding the entire box. "

That's from Bruce Stanley's rebuild guide.

I'm only in the research phase now but will have questions as I get closer to tearing it down. I just left it in and pulled the Jeep outside for now.

Thanks for listening.

 

Has anyone heard from Herm? I ordered rebuilt parts and new (used) gears from him one week ago but have not been able to contact him since. Maybe his computer quit? and his fax machine?
Just checking to see if anyone's got some info. as I'm itching to see if I can get this thing back together!

 

Good news. Herm called and left me a phone message.
Even better news. He shipped my parts last week!