I'm in the middle of stretching my T-19 close into a wide (swapping the guts from a wide 2wd tranny into my 4wd tranny case). I've got the main drive gear and the mainshaft out (that sucker is heavy!) and I'm ready to drive the countershaft out and remove the cluster gear. I had a dummy shaft made up to the specs given in the FSM and I checked it three times with different micrometers, and it is exactly 1.135" diameter. The problem is that this dummy shaft will only go in about 3/8" and even that is a super tight press fit. At this point it is just too tight of a fit to continue driving it in. Looks like if I want to use this dummy shaft, I'm going to have to have a couple thousands taken off the diameter.

So here's the question: What have you used for a dummy shaft? or do you even use one at all? I guess you could just pack the rollers in there with grease like you would on the intermediate shaft on a t-case but it seems to me like it would be a real PITA since there are about 4 times as many rollers in there. Let's hear what you've done.

Check to make sure you don't have a roller jammed up. I used a long ass pipe and beat the sheet out of it.

Joe

It can't be a jammed up roller... I've only moved the countershaft about 3/8". It moves pretty easy with a brass drift, but when I put my dummy shaft in there to drive the counter shaft out, the dummy shaft is too large diameter and is binding up on the case. Did you even use a dummy shaft or just drive the countershaft out?

Just drove it out. Used sch 40 pipe. Then used PVC pipe as the dummy shaft and left the shaft in the freezer overnight before I drove it back in.

Joe

cool, looks like a trip to home depot to check out some pvc sizes... thanks.........

Damn near perfect 'off the shelf' material for dummy shaft: 1" type M copper pipe. The dummy shaft is spec'ed out in the FMS as 1.135" and the 1" type M copper is 1.125" O.D. The 0.010" difference provides just enough 'slop' to allow the shaft to easily and freely slide through the hole in the case but still keep all the rollers and spacers in place. I couldn't find any PVC pipe that was anywhere near that close in dimension.