D300 gear mis-alignment?

[beyer05]

Is this ok, or do I have something wrong here. It is a Tera 4:1 with JB 32-spline front output and Tera rear 32-spline output. The endplay is set on both shafts and I have the thrust washer installed.

[sw99]

Holy focus dude! Can't tell shiat from the blury pics. From what I can see, they look good to me. How do the feel when the yokes are spun? If it's a light drag, your probably good. Do you set up the preload correctly?

[OlBlueCJ7]

Looks like the intermediate shaft needs to come forward. How, I'm not sure. Did you put thrust washers on both ends of it?

[yager]

how did you put the shims in there? Should be 1 shim with a tang/tab on each end of the gear with the tang in a slot in the d300 housing. (going off memory) There probably is a groove on the gear for oiling make sure you didnt use that and double up the washers on the one end..

good luck

[beyer05]

Originally Posted by yager

how did you put the shims in there? Should be 1 shim with a tang/tab on each end of the gear with the tang in a slot in the d300 housing. (going off memory) There probably is a groove on the gear for oiling make sure you didnt use that and double up the washers on the one end..

good luck

I put one shim on each side with the tang. I have the tang facing the case, not the gear.

[beyer05]

Originally Posted by OlBlueCJ7

Looks like the intermediate shaft needs to come forward. How, I'm not sure. Did you put thrust washers on both ends of it?

That is what it looks like to me also, but the intermediate shaft can not move???

[sw99]

[sw99]

Here is pic of one that is properly set up, from the pic it looks offset a bit too;

http://www.rockcrawler.com/techrepor...name=installed

[JeepinDoug]

It's only the front side shaft that has the misalignment. Was the bearing bore machined to the correct depth?
The misalignment like the same as the depth change.

[beyer05]

Originally Posted by sw99

Here is pic of one that is properly set up, from the pic it looks offset a bit too;

http://www.rockcrawler.com/techrepor...name=installed

Yeah, pretty similar. Should be ok.

[beyer05]

Originally Posted by JeepinDoug

It's only the front side shaft that has the misalignment. Was the bearing bore machined to the correct depth?
The misalignment like the same as the depth change.

The misalignment is probably around .050"-.080". The depth in the front output housing is suppose to increase by .120". The machinists notes say that he did do this. But.....I might have to check that, because the misalignment is only between the front output and the intermediate, not the rear output.

Is there an easy way to check without disassembling the whole case again?

[JeepinDoug]

It should be ok, the helical cut on the gear won't thrust the matching gear off enough to hurt it.
As far as checking it, even if you pulled it apart it would be hard to check it. The cast aluminum plate doesn't have a reliable face to check the depth from, (if you had already checked it before machining). The only other place to measure would be the flange thickness between the bearing bore bottom and the seal bottom (the flange that gets the two 1/4" endmill cuts for pressing the bearing cup out).
The specs for machining are on JB's website.

If you wanted to check it you could call JB for that finished thickness callout.
Hopefully the machinist didn't read it as .012" instead of .120"

[beyer05]

Quick thought...I was just outside looking around and noticed that there was a gasket for the front output housing and I used RTV. Could this cause it? Are you guys using gaskets or RTV?

Doug, you think it would be alright like this? What if I install the gasket? That would help some, I guess.

[JeepinDoug]

The gasket is thin, I also used RTV.
The misalignment shouldn't hurt it.

[beyer05]

Originally Posted by JeepinDoug

The gasket is thin, I also used RTV.
The misalignment shouldn't hurt it.

Yeah, not even .010". I am going to run it. Thanks.