chipped counter gear teeth....this is some strange stuff?!?
http://home.attbi.com/~spencerclements/highrangecountergear.jpg http://home.attbi.com/~spencerclements/lowrangecountergear.jpg

an e-mail is in to calmini to rectify the situation.....

the write up for the sumo 6to1 gears that is on orc shows a set of gears like that. supposedly that is the reason the sumos use a larer tooth for the gear sets. it is supposed to help prevent that from happening. i don't know how common it is though.

maybe I should get a credit for the gear and get the calmini 5.8:1 gears.......:D

Break out the welder and fix the damn thing, !!! its only metal !!!Im sure they make a rod that will weld it properly.. Ive heard that JB weld is plenty strong, might give that a try too :flipoff2:

Did somthing cause it to break off like other crap in the case, or did it "just happen" ?


-yag

it sounds like I am gonna have to pull the gear ans send it back into calmini. I've got a trip to moab planned this weekend so I am going to run them and hopefully not break them:D it would suck big time if i did blow the thing apart!!

What was it that made you pull the case apart?
Was it load, or just didn't feel right?

Originally posted by spencurai
it sounds like I am gonna have to pull the gear ans send it back into calmini. I've got a trip to moab planned this weekend so I am going to run them and hopefully not break them:D it would suck big time if i did blow the thing apart!!

I think you outta reconsider this...... I´d say the odds are really good that you´ll end up destroying what´s left and then throw your warranty out the window.

Based on the pics, I wouldn´t run them even on the highway...

BTW, the fact that there is damage to both the large and small counter gears leads me to believe that there was some sort of error in the heat treat of this part. All the more reason not to run them and go after a vendor replacement. If another hunk should break off and enter between other gear teeth, you could be looking at the ENTIRE t-case needing replacement.

0.02

I pulled the t-case to put it in a mighty kong t-case mount. when i drained the fluid i got chunks. the particular instance where i believe the gears broke was about 6 to 7 months ago and it has run since then in this fashin and been wheeled hard!! it has never failed. I dont have a front locker so I dont think I am going to get on it too awful hard. I think it will be ok. I dont plan on driving it to moab. It will be flat towed with the rear driveline removed. it has been this way for a long time so I hope it doesn't blow. I have to make this trip!!


when I look at how those gears mesh together, it looks great!! there is plenty of adjacent tooth meshing with the other gears to make things still workable. I do have some pics of meshing. As far as highway, the high range gear looks the worst. I wont be doing too many highway miles. as far as low range, it is only half a tooth and should still be fine considering the helical nature of the gear cut. I am no expert but it looks like it will survive!!

I am taking my spare t-case down with me just in case.

Is your case set up with the 2wd low option????

Hi Spence -

Don't mean to burst your bubble but we have seen this more than once - even with FACTORY gears and I wouldn't be quick to blame Calmini. That type of breakage is caused from the gears not rotating square with each other which is caused by too much tolerance in the bearings - in effect worn out bearings and/or counter shaft.

OK, they´re your nickels...:p

Good luck...:)

Originally posted by Trail Tough
Hi Spence -

Don't mean to burst your bubble but we have seen this more than once - even with FACTORY gears and I wouldn't be quick to blame Calmini. That type of breakage is caused from the gears not rotating square with each other which is caused by too much tolerance in the bearings - in effect worn out bearings and/or counter shaft.

my case does have the 2wd option and that is what i think caused the initial breakage. the bearings were new with the calmini kit so they couldnt be worn out. i think too much endplay in the countershaft was the cause. it looks like the gear had too much room to move laterally on the counter shaft and too much force was placed on not the entire tooth face. I know it was cause from the 2-lo operation and I will avoid such useage of 2-lo in the future.

now that i look at the pics again i can see how worn bearings would cause the failure of the low range gear. I think the lo range gear came off and ran through the high range gear causeing the high range gear to fail. they are going to get used this weekend regardless!! I will avoid high range at all costs because of the extreme damage to the high range gear.

time for some 6:1 t-case gears in a freshely rebuilt t-case.....:D

let us no what Calmini says

If you are going to get some new Cog's, get the Rockhoppers from Figmo, at least you get customer service.LoL!!
UPS just dropped mine off about an hour ago,SWEEEEET!
And yes I have done that to a set of gears,at least yours still have teeth. Drive em till it Dies!

Originally posted by ghost dog
Drive em till it Dies!


famous last words....:)

well I just got back from moab. my lack of a traction bar and the SSRs at 5 PSI=silly springs.......going up the dome on golden spike, I hammered it snapping the left rear CJ leaf and tweaking the hell out of the right rear. the pinion bound but the KAD shaft from Arizona Drivelines held like a champ. The gears held out through some serious abuse with my temper!! I was bummed about the spring breakage but a used pair of CJ leafs from Moab Offroad saved the day for only 40$:D now I've got to tear down the case and send the counter gear back into Calmini so they can inspect it.