Ok guys, Im in the process of taking my t-case apart, and ive ran into some major bad problem right off the bat---I'm curious what caused it--if anybody else has had my problem, and if it can be fixed.

I am following the IZOOK Pertoworks grsII install http://www.izook.com/tech/samurai/drivetrain/pwgrs2/pwgrs2.htm
as I have been recommended to do (I found on searching threads)

I got all the way to step 3 Remove the center nuts (refering to the center nuts that hold the front input flange and the rear output) and things went bad.

I did as it said in step 2 "Using a pointed punch, uncrimp the large center nuts on the input and rear output flange. Do not uncrimp the nut on the front output flange as its removal isn't necessary.
Note: I used a 1/4 inch very sharp chisel that had been ground down to fit the notch." after which I began step 3.

I broke the nuts loose no prfoblem, all seemed well. then it became tight. I backed it on/off a few dozen times till the nuts came off both flanges---thats when I noticed a huge problem. The nuts had stripped which in turn stripped the last threads on the shafts (both of them). I can best describe the amount of threads trashed are just further than the crimp distance/notch on the shaft. The threads now are non existant on the end of the shafts and cannot be rethreaded. However it appears that I may be able to grind the shafts down 1/4 -1/2 inch to remove the damaged area on the shafts. I then would need a nut that didnt extend where the crimp areas were.

I am pissed about this whole mess and have no idea where to go now. I dont wanna buy another t-case--however it may look like I will have to. Has anybody had the same problem getting those damn nuts off---I could only think that I didnt uncrimp the nuts enuf (damn tough for me) however I am positive I had enuf clearance under then and that I removed the crimp. What caused this--what can be done to fix it--and does anybody have a case nearby (Modesto, CA) cheap heck I dont care if the case is cracked that I could use the shafts out of if thats what I need.

thx for any help.

if you have a diga cam send me a pix moto261@netzero.com i got lots of sammi t-case stuff around ill send you one only one catch you have to pay for shiping k


:massey:

Ok on checking, and thinking--I need both shafts, (the input, and output shafts) and the 3 flange nuts---I have the flanges already--I really dont care about the case itself--like I said--mine is fine--just the shafts took a turn for the worse.

I will attempt to get pics (my g/f loaned out the camera today--however I will get it back tomorrow) and will send pics to people and to post.

I know there is someone close out there with a busted or taken apart t-case rottin in their garage, so please help out---I am willin to pay, and ship---however I would prefer the parts to hit here by fri the latest. as I have a trip saturday. Also the T-case is from an 89---if that matters.

again to all who reply thx

P.S. Im sorry for not thinkin to place this in wanted ad's first, I didn't think it would come to this.

Since the threads are already toast, you would have nothing to loose by grinding off the damaged portion of the threads and also the crimped portion of the nuts and putting it all back together again and running it. To ensure that the nuts don't loosen up, just tack weld the nut to the shaft.

Sure, you'll have problems in the future to take the beotch apart again, but an angle grinder will take care of that. The shafts and nuts are already fawked, so you're out nothing.

That's what I'd do if it were mine. But I'm glad it ain't........ :D

i have a couple of tcases 50 bucks and one is yours i live in brentwood about 50 mins from ceries

thx guys for your help, i dunno if this is a common problem, however when it happens it's a pain. I was able to locate someone who had the parts I needed. Thx again to all!!

This happened to me. I ordered a new nut. I ground down the stripped section of the shaft. I used loctite. I retorqued the nut, dimpled the ring part of the nut. No problem. It has been years.

Geob

I did the same as you---I had a really hard time finding a nut that would work. I did find the only place that had em was the John Deere Tractor parts company. I found they have tons of metric bolts and nuts due to their tractors using metric rather than standard, and since its a tractor---its gotta be huge.