Transfer Case Internal Blues!

[flint54]

My boneyard NP242 was almost too good to be true. $75 and it felt good externally.

Ordered and received all bushings, bearings, seals, chain, and input gear (needed 23

spline).

 

I've got it now fully disassembled, marveling at how good shape each part was as

it came out. Right up until the last one. The differential case was disassembled,

carefully cleaning each of the 8 internal gears and 12 shims and the case halves.

 

As I looked closely, the dismay suddenly came to life. There is a bearing land on

the mainshaft gear (item #22 in the image) where it rotates within the top case

half and it was really galled. The mating bore of the top case half was likewise galled.

They aren't a nice fit any more. I've smoothed the two surfaces as best I can, but the

two parts are sloppy when nested together, about 0.020" lateral freeplay.

 

 

So my puzzle is where to go from here. I've got several hundred $$ into this

T-case so far, and I'm not eager to just abandon it now. I could:

 

A) put it back together as it is and hope for the best

B) abandon this T-case and find another, hoping it's healthier

C) buy a new differential ($900) and press on (not bloody likely!)

D) hunt for someone willing to sell a used, healthy, differential.

 

Who wishes to share their opinions?

[flint54]

Thanks to fellow club member Mike, my choice oif option D is made. What

a great group of folks this place is!