Thread: LT95 Transfer Case Intermediate Shaft Wear

Stirling they are relatively cheap and available I got my last one from All 4X4 in Newcastle.

You need a new one.
If the LT95 is a shimmed one ( and probably for a taper bearing one) you also have to make sure that the gear set is long enough to fit the needle rollers in. That type of wear may be from a short gearset that has tensioned the needle rollers, although usually from swarf from shims blocking the internal oilway.
So measure the gearset also.

Regards Philip A

Jeez , I fully overhauled 100 LT95 transfer cases and never seen or heard of a center diff snapping its case bolts . PhillipA , usually if you over shim the 3 needle roller ( NO taper rollers anywhere in a intermediate assembly ) bearings it results in the plastic cages melting and blocking off oil supply and doing alot more damage than that shaft shows . That shaft shows pretty standard case hardening lifting emanatiing rom the lube holes .Wont be swarf , will be bits a metal coming off the needlebearings ,Check eack bearing , you will see the witness marks line up with oil holes .

There is no easy ,cheap way around it , you need to fix it properly the first time,
This is one of the rare times the workshop manual , is probably the best thing to follow for the novice .
There are basically two sets of measurements/clearance you must get right .
First the bearings , there spacers , and shims total length must be just so.
The whole intermediate shaft assembly must be just a certain length .
Those pegged end washers , those Bronze thrust wasjers must be just so,
Its a case of offering up the assembly ,checking the end thrust and adjusting by changing the endplate or bronze thrust washer thickness ..

Your old shaft will be great as a Dummy **** to use to set up and measure with !
The manual clearly shows all the measurements you need to get right

PS while your there , dont forget to do the Modiication that prevents gearbox oil getting into the transfercase

Originally Posted by 400HPONGAS

Jeez , I fully overhauled 100 LT95 transfer cases and never seen or heard of a center diff snapping its case bolts . PhillipA , usually if you over shim the 3 needle roller ( NO taper rollers anywhere in a intermediate assembly ) bearings it results in the plastic cages melting and blocking off oil supply and doing alot more damage than that shaft shows . That shaft shows pretty standard case hardening lifting emanatiing rom the lube holes .Wont be swarf , will be bits a metal coming off the needlebearings ,Check eack bearing , you will see the witness marks line up with oil holes .

There is no easy ,cheap way around it , you need to fix it properly the first time,
This is one of the rare times the workshop manual , is probably the best thing to follow for the novice .
There are basically two sets of measurements/clearance you must get right .
First the bearings , there spacers , and shims total length must be just so.
The whole intermediate shaft assembly must be just a certain length .
Those pegged end washers , those Bronze thrust wasjers must be just so,
Its a case of offering up the assembly ,checking the end thrust and adjusting by changing the endplate or bronze thrust washer thickness ..

Your old shaft will be great as a Dummy **** to use to set up and measure with !
The manual clearly shows all the measurements you need to get right

PS while your there , dont forget to do the Modiication that prevents gearbox oil getting into the transfercase

Better yet, junk it and fit a tapered roller intermediate gearset

PhillipA , usually if you over shim the 3 needle roller ( NO taper rollers anywhere in a intermediate assembly ) bearings it results in the plastic cages melting and blocking off oil supply and doing a lot more damage than that shaft shows

.

I must be getting poor at english but I thought I said exactly what you said.
I was just warning him that if the gearset is too short the plastic cages etc etc.IE measure the overall length.

Although I have seen one so blocked with shim swarf that when I blew it out with some air , the material flew across the room. I suspect the transfer involved had had EP90 in it.
Regards Philip A

Originally Posted by 400HPONGAS

PS while your there , dont forget to do the Modiication that prevents gearbox oil getting into the transfercase

What is this modification?

Garry

Originally Posted by PhilipA

.

I must be getting poor at english but I thought I said exactly what you said.
I was just warning him that if the gearset is too short the plastic cages etc etc.IE measure the overall length.

Although I have seen one so blocked with shim swarf that when I blew it out with some air , the material flew across the room. I suspect the transfer involved had had EP90 in it.
Regards Philip A

whats the story with EP90??

Originally Posted by clean32

whats the story with EP90??

EP 90 used to have an ingredient that ate brass / bronze shims in LT 95's. Some EP 90's may still have it. Rick 130 would be the man to explain. PhilipA had sad first hand experience in the past, from memory.

cheers, DL