I pulled everything from the Crank (including seal) to the rear axle today. This is a follow up subject to "Getrag Down". Interesting things I found were as follows, NO OIL in trans. None! I topped everything off about 2 months ago after resealing the PTO covers. The only places I can think it went was some out the rear seal and the top cover was very loose. Two of the bolts had backed out about two threads. The gasket was very hard and had migrated some at the loose bolts. I can only speculate that as the gears sling oil it was going out the cover? The bottom of the truck has been very wet but I couldnt find the leak.
Whoever put the last engine rear seal in, left the tool there.
One of the bolts holding the Engine rear plate had backed all the way out. But just that one.
The transfer case still had all its oil and shifted well. I had a problem with getting into 4 high before. It turned out to be interferance with the lever and the tunnel.
So after all of the dirty work was done I started to try to take the trans apart to have a look at the damage. It looks like all the gears and shafts are ok. The input shaft bearing is what got HOT and was making ugly noises. The pocket bearing got a little dry too. But the mating race on the end input shaft apears to be in good shape.
It looks like I will need a new 3-4 shift fork though. I think that when things got hot there it got wasted.
So far all the disassembly I have done is to get the top gearset and input out. I have questions on the rest of the take apart.
1- How do I get the bearings off the shafts?
2-How do I get the counter shaft out? Is the answer behind the rubber plug at the front?
3-And lastly, What takes up all the latteral forces on the top gearset? Only the preload of the front/rear and pocket bearing? That does not seem like it would work.
Anyway thanks for wading through this and for any answers you have.
CC. from TDR