Thread: Mystery Item causing Transfer case havoc.

Ouch!. The small round thing is a locating peg for the outer thrust washers on the standard intermediate shaft. There is one on both ends of the shaft. I am guessing that is what caused the damage to the gear. There probably will be damage to the input gear on the intermediate shaft that meshes with this one. Looks like a transfer rebuild to me.

Yes, that is what it looks like. There is some marking to the mating gear, but not too bad from a visual inspection. luckily, only drove it a couple of hundred metres. I can feel a fair bit of movement in the front gear on the intermediate shaft. feels similar to loose wheel bearings. I assume the tapered roller bearings are shimmed for preload, is the relevent section of the repair manual available, to your knowledge?

...And, upon dropping the intermediate shaft, we find this
thrust crop.jpg
which are now, of course, no longer available. So, do I get a new one made, or would I get away with facing this one?

What is the box out of? Just trying to ascertain whether it's an army LT95 or a normal one we are talking about here as the normal ones only had a roller bearing intermediate shaft. If it's a tapered roller bearing intermediate shaft assembly as that damaged plug (FRC9394) indicates maybe it has been retro fitted. Any chance you could get a photo of the rest of the intermediate shaft assembly and advise the box serial number. AFAIK that plug is still available but not cheap. Whether you can reface it or not depends on how deep the furrows are - bit hard to see in the pic. If they are only very shallow it would be ok but if they are deep you are going to have too much clearance behind it when the shaft is tensioned.