I ordered a new front sealed bearing from Novak, as Walck's doesn't sell them. Decided to try and help seal the front of the case with the sealed bearing and sealing the oil return hole.
New T-90-C shaft with sealed bearing installed
New T-90-C cluster gear from Walck's
I used Rick Stiver's rubber band method to get the needle bearings in the cluster gear.
I bought a 3/4" dowel for the job, but when I got home and measured it, it was .70" in diameter...
I tried putting the bearings on the dowel with the rubber band, but because the dowel was a bit small, it was 1 bearing short to get them all on there smoothly. So, I used the actual shaft instead which worked great.
The pic is before I greased the bearings with assembly lube. Simple to slide them in the cluster gear a little at a time, cutting the rubber bands as they go in. Once I had them in the cluster gear, I pushed out the steel shaft with the dowel to hold them in place while putting the cluster gear in the case.
Here's the cluster gear in place at the bottom of the case, ready for the input shaft to go in.
The synchro gave me some grief... I replaced the little synchro plates with the new ones from the small parts kit, but they were a hair to wide to fit into the synchro gear. I filed them down to fit, put it all together, and found that it wouldn't shift unless I used a hammer to move the parts. At first I was thinking that it would be stiff for a while until it wears in, but I couldn't shift it with the shifter cane at all. so, pulled it all apart again, and put the old synchro plates in and it works fine. They had been replaced at some point in the past, and it was shifting fine before I tore it down.
Before I put the t-case back on, I pulled the shift interlock pill out so that I can shift into 2wd low range while trying to steer/maneuver with the front lock-right locker.
Ready to bolt back together
Everything back in one piece, ready to go back in Barnacle Will
Going to try and get it back together today.
Still need to order shift rail seals for the cane shifter, they are missing and part of the leaking...
More to come.
Pete