84-85 Trucks & 4Runners 2nd gen pickups and 1st gen 4Runners with solid front axles

Regeared Transfer Case, Might Have Extra Parts... Need Advice!

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Old Jun 1, 2013 | 11:24 AM
  #1  
frankryzzo's Avatar
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From: Bodymore, Murderland
Regeared Transfer Case, Might Have Extra Parts... Need Advice!

84 4runner, g52 trans, SFA, single transfer case

I re-geared my transfer case and put it back together with a twin stick case. Cleaning up the work area I found the one thing I didn't want to see... an extra ball bearing. I know it isn't from the detent springs since both sticks function properly and lock at each setting. I tested everything before I installed the case, and everything seems to function properly. Low and high gear both turn the output shaft when the input is turned. 4wd engages and spins both output shafts when the input is turned.

As far as I know, there are only 5 ball bearings in the case... 2 for the detent springs, and 3 on the main shaft, 1 for the low range, 1 for the high range, and 1 for the speedo gear.

Question 1: Does anyone know if there is an additional bearing that works with the interlock pin that locks the 2 shift forks together? I removed this pin for the twin stick kit, and I'm not sure if i pulled a bearing out with it or not. There was some time between taking it apart and putting it back together, so everything isn't fresh in my mind. (It's also possible that the bearing was loose on the work station because my friend had done the same to his Jeep transfer case the week prior, but I know nothing about Jeep cases...)

Question 2: If one of the bearings from the main shaft is missing, can I test drive the 4runner without causing damage to determine if everything works? I would assume that either the speedo, high or low gear wont work if the ball bearing is missing because the shaft would just free spin without turning the respective gear.

I don't want to strip it down if I don't absolutely have to. I can't get new gaskets without paying for a transfer case rebuild kit, and I sealed up the gaskets with permatech thinking I'd never have to get into the case again.

I'm kinda freaked out about the extra ball bearing and any advice that can be offered would be greatly appreciated!
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Old Jun 6, 2013 | 01:49 PM
  #2  
frankryzzo's Avatar
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From: Bodymore, Murderland
So... it was the ball bearing for the speedometer drive gear. I just went for it and stripped it down again to make sure everything was ok. The permatech on the gasket actually helped me reuse them since it stuck to the gasket way more than the aluminum casing and allowed me to get them out without damage. The funny thing is I realized how it happened, as it fell out again during reassembly. If the rear output shaft isn't locked in place, when you tilt the case forward to torque the bolts or put in the detent springs, or in this case slip on the final casing, the speedo gear can slide forward enough for the ball to drop out.
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