T-Case Gurus can you help me with my 205?

[morphed86k10]

It's been a while since I posted at ck5, I wish it was under better circumstances but I need some help!

I finally crawled under my truck to bolt my twin stick shifter back down. One of the bolts had vibrated loose and the remaining two couldn't hold the shifter securely, causing my t-case to not fully go into neutral on the front shaft and grind and catch gears while trying to drive in 2wd. Or at least I thought that was the problem.

I secured the shifter and realized the front output shaft had about .5 inche of play, I could slide it front to back about that much. When the shifter was in neutral for the front stick, I can slide the output shaft and engage gears, or slide it the other way and it free wheels like it should I noticed on the back of t-case, the cap that covers where the front output shaft rides had backed out almost a half inch. I tapped it back flush and the play in the output shaft is gone. I'm worried something is wrong internally that allowed the shaft to walk that far. Does anyone know what caused this?

For a little background, The t-case and twin stick shifter is a rebuilt custom unit from a reputable source, and I've had it in the truck for about 3 years, although it probably only has 2-3 thousand miles on it.

Sorry for the length, any help would be appreciated!

 

[4X4HIGH]

The t-case and twin stick shifter is a rebuilt custom unit from a reputable source

With that said why not call whoever it is you got it from and ask them about it.

The "cap" on the rear cover for the front shaft is actually a torrington bearing that the front output shaft rides in on the rear of the shaft. With that having moved would explain why the shaft could be moved .500" (sort of anyways). I personally wouldn't think the shaft could move that far with the rest of the internals in place. It's been too long since i've had my 205 apart to remember if it's possible.

 

[JDNobodi]

Is the front output yolk nut tight? That the only thing I could think of that causes your problem besides the transfer-case not assembled right. The end-play should be controlled by the ball bearing on the front of the case, not the needle bearing in the back.

 

[Mudstud]

If I understand correctly, you are saying that the big aluminum plate in the back of the t-case [big round thing on the right in the pic)

backed out about 1/2"? How can this happen and you not loose all your gear oil?

I'm thinking somehow a snap ring broke! Maybe the one infront of the main front output bearing?? This place has a diagram on the internals.

http://www.drivetrain.com/205transfercasesillust.htm