So.. without taking the t-case apart what is the indication of slop in the spline/gear? I have a klink sound that is either r&p, drive shaft spline or the aforementioned, I have checked u-joints already. Maybe a group buy..
Remove the transfer. Weld the existing output gear to the PTO spacer then weld both to the PTO drive gear. You have just made a McNamera gear for about $.40 in wire. I have done this a pile of times and have many thousands of miles on them with no problems at all.
Spend a bunch of money to be able to say you have a McNamera gear.
spacer then drive gear, spacer is not splined and the PTO gear has rather short surface contact area onto the shaft; especially compared to the McNamera which will give you about 3.5" of new contact area.
To be afir the McNamera is a better set up but welding all the crap works really well and will work for a long time.
A forum community dedicated to custom off-road vehicle owners and enthusiasts. Come join the discussion about trail reports, builds, performance, modifications, classifieds, troubleshooting, fabrication, drivetrain, and more!