falcotim

Well, on my drive from Salt Lake, Ut to Tucson, AZ, a vibration started in the rear end. Checked everything and there was no play or anything, so kept going. Fluids were good. Kept happening and found that the t-case rear output shaft nut had backed off. It backed off pretty far. I tightened it up and got going again and the vibration was gone, however there is now a popping sound coming from the t-case on deceleration and in reverse.

It's a dual case with the inchworm adapt and marlin gears... the sound is coming from the rear case, as I can feel it through the shift knob.

I had to replace the output seal, so I pulled the rear cover of the t-case off and looked inside and spun it by hand. Nothing out of the ordinary, and when I drained the oil, there was nothing unusual in it.

I put it back together, and the sound is still there. Anybody have any ideas on what it might be? Again, it's a popping sound during deceleration or in reverse, so it makes me thing that the backside of one of the gears is jacked up. Hopefully not one of the marlin gears!

It happens when the t-case is in hi range and 2wd BTW, if that matters.

I've found a fwd shift t-case out of an 84. Mines a top shift. Does anybody know if parts from the fwd shift will swap into mine? I'm tempted to just tear it apart and see what's going on, but if somebody has any ideas, I would prefer to go another route.

It's an 85 4Runner on 37's with the dual cases, stock 22re.

waskillywabbit

iTrader: (-1)

You running a double cardan joint or a single u joint next to the rear output?

Everything is the same except shift forks and rails.

Etype R

Could be bad bearings, allowing the gears to shift under power.

And like Wab said, everything is the same other then the shift rails and forks. You can use the rails and forks from your top shift case.

falcotim

Sweet! I was hoping that! Yeah, I think it's either a bent main shaft or bad bearings. We'll see when it's apart.

I'm running a single u-joint shaft, but no vibes before this happened. a week before this happened, I drove 12 hours in 2 days with no vibes or anything of that sort.

dropzone

iTrader: (6)

more than likely bearings, pretty hard to bend a shaft...
there are some forward shift to TS link on page 1 or two of my misc ideas thread that is in my sig.

good luck

Etype R

He won't need to modify any thing if he takes his stop shift forks and rails from his broken case, and installs them on the forward shift case