Just as a follow up....I replaced the gear pictured above with a good used gear from Herm and the noise is all but gone...The transfer case is pretty quiet in all gears with just a hint of a whine at around 40 mph....I'm guessing that if the intermediate gear was that worn the output shaft gear must also be worn, and is probably the source of the slight whine at about 40....but I did not change it..that would require removing the TC....
So I'm very pleased with the result.
Here are a couple pictures of the bore of the gear I removed, same as the gear pictured above..
I got the new barrel gear back. I'm hesitant to install it. They made no mention of whether or not the first barrel gear was faulty or out of spec.
I'll have to give that intermediate gear a good going over before I re-install the OD...
I've read that the intermediate gear can be changed along with the shaft and bearings without removing the transfer case..Anyone done it?
Maybe I have a bad intermediate shaft though it was new 600 miles ago...but you'd think it would whine like a hyena all the time if that were the case...
Maybe, I don't know......Could it be that it wasn't seated properly? I had the 110-120 ft pounds on the special nut just as required....
I put an OD in the CJ-5 and that went fine..we had to shim it as it wanted to pop out of gear but it is quiet and reliable now. It's been in there for a couple years...
This OD was a bear to install...like it just didn't want to go in there...but it finally did....
I sent the barrel gear back to Herm and he is going to send it to Advance Adapters to be checked out.....if they can't do something with that gear I'll need to get a replacement...
Looks fine to me. No pitting or galling on the face of the teeth. Both the drive and coast side of the teeth are still the same contour. (the drive side going forward takes a lot more wear than the opposite side) Usually there is more wear on the inside/rollers/shaft with this gear than the teeth.
