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This is a pic of the front boss for the intermediate gear shaft on my T-90 transmission. This seems pretty rough and may have been caused by the trans eating its oil collector. Is this too rough to reuse? Is there a way to machine this down or will this increase the opening between the front and back of the case too much? Or can I just slap a new thrust washer in there and let it work the surface back smooth?



Thanks.

Jim

Usually when in doubt, replace it. That is my motto.

Others with more tranny experience should be able to tell us more.

That's not so uncommon a wear pattern. Caused by the grit and grime over the years carried in the gear oil and trapped between the case and thrust washer. I'd just wait til I assemble it and if play is within limits go with it. If not visit a machine/welding shop and see if they can weld material back and machine it smooth to closed the clearance gap.

In our GPW the transfercase seems ok, but after replacing the intermediateshaft ( from Novak), The jeep runs a lot quiter. I think it is the only part wich is the weakest one. Replacing this part is essential when doing a rebuilt, normaly the washers do not turn against the housing, so after installing a new set shaft, washers and rollers there can not be a problem anymore.

just my expierence
Erik

Thanks for the replies.....I agree......the thrust washers should not spin.....but its plainly evident mine did......for whatever reason.......maybe there's already an excessive anount of space between my bosses and the tabs on the washers can't hold them......or my clusater gear is overall too short......or it was the sheetmetal part of the oil collector that's MIA. My plan at this point is to go with one of those complete T-90 rebuild kits.....and just see how the gap closes with an all new cluster gear and thrust washers. At this point.....if the gap is too great.....I am leaning heavily toward replacing the case as there are other problems with the case which make it marginal......like the center-punching around the intermediate shaft hole on the back end of the case. This case seems to have always leaked.....or at least somebody sure did a number on it trying to get it to seal up.........whoever worked on it last either had stock in Belknap's rtv division or just had a lot of it laying around with nuttin to do........cause it was like Jesus........it was EVERYWHERE!!!! I'll do it right once.......if it leaks......then its getting replaced. If it doesn't spec out now because of the intermediate gear thingy.......that'll just be one step eliminated......the leaking step. Biggest decision now is......there isn;t a lot of price difference between and internal parts kit and a new completely assembled xmission......decisions....decisions......

Jim