need help with IX transfer case

[Ceeker]

My buddy and I had a few 5sp transfer cases lying around. One was rebuilt; the bad one was auto and we decided to use the input shaft from the std, front case from the auto and the rear case from the std to get the auto working again.

here is our findings: after installing the cases back together we got binding inside. We split the case and found the basket collapsed against the c clip which holds the basket in place.

would anyone have experience with these components and possible shed light on what might we be doing wrong or missing?

thank you.- Ernie

[flyboyx]

i took a couple xfer cases apart recently. i should be in a position to help you out but i really don't understand what you are talking about.

here is what i can say for a fact:

i took apart 4 transfer cases in the last month or so. 1 was an auto, 3 were manual. there was enough parts there to rebuild 2 cases. as posted on the other forum and in other places on the internet, except for the input shaft and the front housing half, auto and manual transfer cases are indeed exactly the same. everything internal is the same. the rear half of the housing is exactly the same. i have no idea what you are saying when you refer to "basket" but i might guess you are talking about the spider gear cluster?

if you are experiencing binding in your case, i can think of one likely reason for this and one unlikely reason.

the likely one: you didn't put something together correctly. go to real oem and print out the picture of the expanded view of the inside of the case parts. it is far from perfect, but use this diagram to help you put it back together.

the unlikely one: you used the chain from one case and used gears from another. it is remotely possible that the chain you used is worn out and sloppy and thus binding on gears that it hasn't worn into.

[Ceeker]

Hey! thanks for posting. just to clarify;
We used the same gears and chain from the donor.
We aren't entirely sure "what" happened but my buddy got it to work. He tipped the tranny over onto it's end. He suspects that something slipped back towards the case and therefore wasn't able to assemble it. the problem corrected itself.

thank you for taking the time to post. it was an experience lets just say...
I personally wouldn't remove and install one of these again...what a Bitch of a job!!!

[flyboyx]

:0)

[nando]

I forgot about this post, I think you're talking about the "bell" #13 here:


I've had the same problem. Unfortunately if that's what you mean, it could be damaged and needs to be replaced. What happened was you didn't have it indexed properly - the teeth of the "bell" go into the slots of the VC. If you don't have it seated into the slots when you tighten it down, you'll crush the bell.

If it is bent and you don't replace it, I don't think the teeth will properly interface with the VC. effectively, you'll have an open diff. Same functionality as a burned out VC.

I'd taken apart my TC several times without having any problems, so I was a little surprised when I put it together and it wouldn't turn. Then I took it apart again and saw that #13 was bent. Fortunately, I had a spare from an auto TC. Getting it off the gear is a PAIN. the circlip is huge, but even when you get that off, you have to really hit the gear hard to get it off the "bell". Getting it back together was easier, at least..