Installation
date: 10/16/99
Installation
continued:
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This is
what the t'case will look like after removing the rear half.
I got lucky and had all the silicon sealant come off on the
rear half, so I didn't have to worry about cleaning the front
half of the t'case. You can see bits of the silicon still left
over though.
Pull the
spring off the shift rail and set the spring aside.
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Now slide
the front and rear output shafts out of the t'case, the chain
will come out with them. You can remove the shift ring with
the main output shaft, or leave it in the t'case. I figured
it would be easier to just leave it in. You can see the shift
ring still in the t'case in this picture.
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This is
the main output shaft and chain. You can also see the speedo gear
housing and front yoke. There is a large lockring on the front
of the main output shaft. This must be removed so you can remove
the synchronizer from the output shaft. This is where the very
large lockring pliers come in handy. |
| Here are
the two output shafts side by side. The bottom one is the new
JB output shaft. Notice the difference in diameters between the
two output shafts. According to JB's website, their new output
shaft is 54% stronger than stock. |
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Unfortunately
I didn't get any photos from pressing the new bearings into
the synchronizer, but the JB instructions have good diagrams
showing what to do and how far to press them in.
Here you
can see the synchronizer, washer/shim, and large lockring reinstalled
on the new output shaft.
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| Lube the
new output shaft with some ATF, then put the output shafts back
in the chain as shown, and slide the assembly back into the t'case. |
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This is
what it should look like once you get the output shafts and
chain reinstalled. Be sure to put the spring back on the shift
rail.
At some
point you will need to clean all the old silicon off the two
t'case halves so that you can seal them back up. If you have
silicon on the front half of the t'case, I would recommend cleaning
it off while you have the chain and output shafts out so you
don't get silicon flakes all over them. I used a round stiff
wire brush on a drill to take the silicon off. It took a while,
but worked very good and didn't scar the surfaces.
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Once you
get all the old silicon off, you can apply new gasket maker.
I used UltraBlue RTV Gasket Maker and it seems to be working
very well.
In this
shot you can see the back of the oil "pump" and its
pick-up tube. Make sure you get the pump and pick-up tube lined
up correctly before reinstalling the rear half of the t'case
and sealing everything back up. I had some trouble getting the
pump to slide over the new output shaft, so make sure you've
lubed the new shaft up well with ATF.
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Finishing
it up...
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