Transmission and Transfer Case rebuild

[macrisel]

Gun,  the only tower I took apart was my original one, the replacement one out of my '47 truck I left alone and just cleaned it up and installed it.  After comparing it with the other two, it looked and felt really good and I didn't want to tempt fate and mess it up.  It even had the original plugs in the end and wasn't leaking there.  Like you, I replaced the plugs on my original tower.  After about the 4th shift, one of them popped out, ricochetted off the bellhousing, ended up in my lap and scared the crap out of me.

I followed the rebuild guide at the end of Rick Stiver's transmission guide to take the tower apart.  It is really pretty simple to do, however in hindsight, if there is nothing wrong with your tower I would not worry about it.  Unless you have a bad fork, rail, poppet ball/spring, or cane you are really just taking it apart and putting it back together again.  All of the things I mentioned should be pretty easy to examine without taking it apart.

Carl, I really like the idea of putting an o-ring on the rails to slow leaks there.  Would you also hone the inside of the case to eliminate any pitting?

[Carls_jeep]

If the bore were to worn or pitted it would have to be repaired. If only pitted you can use plastic metal and then smooth the bore out with a reamer and you may have to hone it some. If worn over size the bores would have to be sleeved and that may be a problem.

I think mine are leaking and I have considered doing the O ring repair. Even it there is slight pitting at least the O ring would slow the leak considerably. Heavy pitting may wear the O ring out to fast.

The O ring would have to be put in the right spot so it stays inside the bore of the cover during the shifts.