Series 3 Transfer Case - Intermediate Shaft Endfloat

Kiwi Landie · Mar 7, 2021

Hi All

Rebuilding transfer case and hit a snag. With no shim, just the thrust washers, I get about 9 thou of endfloat. With my thinnest shim (6 thou) in place as well, I get 3 thou.

Anyone got any advice - shim in or shim out? Is it critical?

Thanks very much
Andrew Palmer

lynall · Mar 7, 2021

S2 manual says 4 to 8 thou, and I would say a little looser is going to be safer than a little tighter?

tottot · Mar 7, 2021

+1 on the above.

Blackburn · Mar 7, 2021

As its a helical gear in high range going on /off load it will float fore and aft I would accept the three thou , the copper faces will wear and gap will grow over time especially if thrusting for and aft.

tottot · Mar 7, 2021

Three thou will not allow for much heat expansion when driven, then things may get even hotter.

rob1miles · Mar 7, 2021

My vote is 3 thou, because the ally case expands quite a bit more than the steel gea. You can tell that because the output shaft is on a preload and I can say from experience that it takes about 8 thou to get that preload.

Kiwi Landie · Mar 7, 2021

Hey thanks guys. I'll rub down the back of the thrust washers on some emery/glass and see if I can get 4 thou with the shim in.

Cheers
Andrew

Series 3 Transfer Case - Intermediate Shaft Endfloat

Kiwi Landie

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lynall

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tottot

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Blackburn

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tottot

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rob1miles

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Kiwi Landie

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