Trust but Verify

[Tchara]

Hi all!
I'm in the process of installing an emergency brake on my CJ3a. When I purchased the jeep, someone had removed the complete system. I bought a used backing plate and drum, and purchased new shoes and hardware.
I have disassembled the flange and rear housing off the transfer case, and am ready to start installing everything.
I have a few questions that may seem obvious, but better to ask then start over.

1. The speedometer gear looks really good and seems to be working, although there is no speedo cable...(yet). Should I put any type of lube on the gear before installing, or will the transfer case oil lube it?

2. When I purchased the new seal, it came with a felt washer, but the seal I took out does not. Do i put the felt washer behind the seal, or use it at all, since there wasn't one when i removed the seal.

3. I purchased a new gasket for the housing. I'm assuming the gasket goes between the transfer case and housing, and not on the backing plate. Do I need to put a gasket on the backing plate. Someone used permatex in lieu of a gasket, and I think that's where the leak was. The seal and yoke seem to be in pretty good shape, as well as the output shaft bearing. There is very little play. I did purchase a new yoke just for giggles.

4. Should I use thread sealer on all the bolts on the housing?

Any other tips and insights will be appreciated.

[Rus Curtis]

I would recommend the rebuilding guide from Rick Stivers.

http://www.willystech.com/wt/Model18TCase/Model18TransferCase.html

But I'll offer some of my ideas.

1. The speedometer gear looks really good and seems to be working, although there is no speedo cable...(yet). Should I put any type of lube on the gear before installing, or will the transfer case oil lube it?

No lube is needed for the gear - it's inside the rear cap where the gear oil is.  I don't think it'll harm anything to put a small dollop of grease on the tip of the secondary before inserting into the cap.

2. When I purchased the new seal, it came with a felt washer, but the seal I took out does not. Do i put the felt washer behind the seal, or use it at all, since there wasn't one when i removed the seal.

The felt is inserted in the dust shield on the yokes.  Some have found the felt too thick and have cut it in half to get it to fit.  Others just leave it off.

3. I purchased a new gasket for the housing. I'm assuming the gasket goes between the transfer case and housing, and not on the backing plate. Do I need to put a gasket on the backing plate. Someone used permatex in lieu of a gasket, and I think that's where the leak was. The seal and yoke seem to be in pretty good shape, as well as the output shaft bearing. There is very little play. I did purchase a new yoke just for giggles.

Applying sealant with/without gasket can leak if not applied smoothly, directions skipped or any debris on surfaces.  This is surgery; keep it clean.  In the SM, fig 36, the gasket appears on the outer surface of the rear cap (indicating behind the brake backing plate) vs. with the shims.  A-17 and A-21 in the rebuild guide for shims.

4. Should I use thread sealer on all the bolts on the housing?

This isn't a bad idea on any bolt that enters a casing containing fluids. If the bolt doesn't enter the cavity, then no thread sealer is needed.

I haven't been into my Transfer case much (I really need to - to resolve a problem) so hopefully others may add suggestions.