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Old 03-14-2012, 09:22 AM   #176 (permalink)
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Yep. All work fine. No noise. Fifth gear, rapapapappapa....
.
Is this free wheeling? if it is that sounds like ressonance.. does it occur in other gears if you let the rpm drop?
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Old 03-14-2012, 09:25 AM   #177 (permalink)
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I am by no means an expert but here's my take:

Patience man, patience. Just about every time I have tried to cut corners to save time I have paid the price later. Go back through your thread and look how many instances that you have said "f-it, close enough". In the end all those decisions add up. You may not have a ton of budget to work with, but you seem to have one resource that is just as valuable, if not more so; time.
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Old 03-14-2012, 09:32 AM   #178 (permalink)
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Is this free wheeling? if it is that sounds like ressonance.. does it occur in other gears if you let the rpm drop?
Yea, free wheeling. Its a really bad clicking sound. Hard to say with the RPMs; exhaust is so damned loud.

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I am by no means an expert but here's my take:

Patience man, patience. Just about every time I have tried to cut corners to save time I have paid the price later. Go back through your thread and look how many instances that you have said "f-it, close enough". In the end all those decisions add up. You may not have a ton of budget to work with, but you seem to have one resource that is just as valuable, if not more so; time.
Just getting anxious. I want to wheel!

I'll go take a video of it right now. Its's going to take several hours for it to upload.

Here's the output seal. I mean, it doesn't look bad...

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Old 03-14-2012, 09:42 AM   #179 (permalink)
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I would throw the rear shaft on and take it for a heat down the road. As Shuduck said, it could just be some resonance thing in the case or trans. I can tell you that my 6.5:1 case is kinda noisy, particularly in the higher gears in low range. However, I've had it together for almost two years and it has not given me any issues.
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Old 03-14-2012, 09:44 AM   #180 (permalink)
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3rd or 5th doesn't matter at 50 its the same speed of the transmission and t-case. Just engine rpms are different.

Tim
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Old 03-14-2012, 09:49 AM   #181 (permalink)
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Took a video. They're short so hopefully it won't take too long to upload.
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Old 03-14-2012, 10:26 AM   #182 (permalink)
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Here's the noise I have going:

http://youtu.be/5VHJCRPyi_Q

I have a longer video that shows me going through 2H 4H and 4L.
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Old 03-14-2012, 01:38 PM   #183 (permalink)
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Here's me going through all the gears n' stuff.

http://youtu.be/Y6eQ_MUMtuE

I didn't work in the garage today. My knees are a bit swollen, I have a sweetheart coming up to visit tomorrow, and if I wanted to, I could pull the Zuk outside so Dad and I can get the boats ready. I figure I still have a few weeks before everyone else in my group is ready. Going to take a break for a couple days. This thing is kickin' my ass.
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Old 03-14-2012, 01:43 PM   #184 (permalink)
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ever think maybe it's 5th gear... that's bad?
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Old 03-14-2012, 01:48 PM   #185 (permalink)
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Its coming from the t/c though.

I can crawl under there and it blatantly coming from there.
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Old 03-14-2012, 03:13 PM   #186 (permalink)
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If it does it in every t-case position, only in 5th gear, it HAS to be coming from the transmission. It just doesn't make any sense that it could be coming from the t-case.

Tim
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Old 03-14-2012, 03:16 PM   #187 (permalink)
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Iunno. Maybe in fifth its spinning so fast that something has gone awry. I also have zero load on it. I should connect the rear shaft to it and see what happens. Ugh, I really don't want to go down there right now. Need a day or two off of beating my head against a wall.
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Old 03-14-2012, 03:33 PM   #188 (permalink)
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5th and 3rd or any other gear are same rpm at a given speed. It's the engine rpm that changes not the shaft speed.

Tim
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Old 03-14-2012, 03:37 PM   #189 (permalink)
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then put it in 4th and rev it up
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Old 03-14-2012, 03:46 PM   #190 (permalink)
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then put it in 4th and rev it up
That's going to be a two person operation. The exhaust on this thing is stupid loud and you can't hear shit over 4000. I'll have to crawl under there while someone revs it; which my neighbors LOVE.
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Old 03-14-2012, 09:39 PM   #191 (permalink)
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5th and 3rd or any other gear are same rpm at a given speed. It's the engine rpm that changes not the shaft speed.

Tim
Well the input shaft speed would change with rpm and the counter shaft gears are meshed with the input shaft gears right? (the few I have rebuilt have been that way). So unless Toyotas are different only the output shaft would be at the same rpm at any given speed.

Put it back together, drive it and go from there.
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Old 03-16-2012, 11:11 AM   #192 (permalink)
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Okie doke. Got a few more answers today. Its not the transmission. I pulled the intermediate shaft and threw it in fifth gear. No noise.

I pulled the plug on the t/c, metal slivers came out. Which leads me to believe that the gears are rubbing on the walls of the t/c. I yanked the entire thing out and split it apart.

At higher speeds, do the gears, mainly the center gear on the counter shaft, move around at all? The gears are so close to the wall I can't even get a LowRange business card between the gear and the wall. I did use a Dremel tool, but I don't think I ground enough away. So I'm going to do that tonight. That's the only place that it even comes close; and its CLOSE. If the gears stress or move in the slightest direction, they'll hit the wall. I'm thinking with the torque and high speeds it must make contact. I think I can even see the marks on the teeth of that center gear.

Grind it down tonight, put everything back together, and go from there I guess. I'm really going to try to get that counter shaft locking pin bolt out too. I have a tap with I will use as well. What I had on there was a bit TOO hack.
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Old 03-16-2012, 11:28 AM   #193 (permalink)
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are the metal filings steel or aluminum?
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Old 03-16-2012, 11:35 AM   #194 (permalink)
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I'll have to take the magnet from the drain plug to see. Same color as the case so I imagine its from that. I have PT in 20m. That last for an hour so when I get back I'll check and see. I kept the oil that came out in a cleaned out coffee can.
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Old 03-16-2012, 12:02 PM   #195 (permalink)
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Anything stuck to the plug?

Tim
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Old 03-16-2012, 04:20 PM   #196 (permalink)
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Took a LOT more off the walls of the case.

Drilled and tapped a hole for the counter shaft key.

I'm a bolt short because of the hole I tapped. The cradle is on, but I'm going to have to go to NAPA tomorrow and get a couple more bolts.

If this doesn't fix the problem, I'm taking a major long break. I've burnt 80% of my oil fund for next year. I go back to work in two weeks or so; until then I'm getting 50% pay and its not fun. I pretty much have zero more motivation. If I have to play spotter and ride bitch, I'm fine with that.
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Old 03-16-2012, 05:22 PM   #197 (permalink)
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Quit being a baby. It's gotta be something! Be patient and don't hurry so much.

Tim
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Old 03-16-2012, 06:11 PM   #198 (permalink)
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Quit being a baby. It's gotta be something! Be patient and don't hurry so much.

Tim
Some of us can't go out and buy rigs already built.

I bet the Zuk will still be out before your TJ ever hits pavement. haha
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Old 03-16-2012, 08:33 PM   #199 (permalink)
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Question

You'll figure it out
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Old 03-18-2012, 10:33 AM   #200 (permalink)
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Still grinds. GSSFC (Tim) took a look at it and seems to think its the bearings.

I'm all done with this. Samurai is in my side yard without a transfer case. If anyone wants to make an offer on a piece of shit samurai that doesn't work hit me up. its got a new clutch, machined flywheel, spool in the rear, missing links w YJs, and autometer gauges. t/c has 6.5 gears but they grind like hell. best bet would be to toss out the entire t/c with the gears and start over. also have a set of stock tires, some steel, and a 10' length of sched 40.

Tim is going to take a look at the t/c. But I give up. Its blatantly obvious I can't fabricate. I've got $400 in the bank right now with about $300 of bills on the counter. My oil fund for next year is GONE. I'll spend 8h a day on this piece of shit and it still doesn't work after four months.

Going to spend the summer riding bitch and taking pictures. Do some fishing too.

I tried to do this on a low buck budget, but as a home owner making $16k a year is harder than I anticipated. My skillset requires me to mostly work with bolt on parts and pay others to do gears and roll cages.

I love wheeling, but I just can't do it anymore. I think its just best to face the facts and cut my losses.
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