Status update... I've moved the 5th driven gear a whole 1/8th of an inch... that's being optimistic though... it has moved, I can see the bearing cage behind it has some wear, I'll see about replacing it... i've pretty much mangled the retainer plate with the crowbars getting that damed driven gear off

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got it about 1/2" off now, my neck is getting pretty damned tired and I'm starting to lose daylight, got the torch back on it warming it back up again too

OUCH

Here's the other OUCH I found... crappy pic, but I think the point will still come across
Attachment 36080


And, after 3 hours of prying, heating and hammering, I got the driven gear off... whew

press fit:ouch:

Wow, 4 hours to take it apart and 10 minutes to put it back together, ... isn't it usually the other way around? Tomorrow I tighten the locknut and put the rest of it together.

What a day:dang::argh::scare2::bat:

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I don't remember it being that hard to put on there... this gear was snug but not a press fit... perhaps the banging gears tightened things up a bit

:yeah: Way to go bro.

OK, back at it.. have to put a new transfer case rear main seal in... the one I put in last time was crappy, it didn't have a boot, this one has a boot and about 4 sealing lips... should be a bit better... the trick is to get it on there without getting covered in oil


I hear the recommended oil change interval on the NV4500 is 16000 miles under heavy service... you'd think with that frequent a change interval they'd have thunk to put a drain plug and a decent filler onto the bastards... I'm going to put my bucket of gear oil in a tub of hot water for a while or I'll never get it in there

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Well, things aren't quite going my way.. the new seal is 1/2" bigger than the old one... bloody morons at the tranny shop! and I'm having a heck of a fight getting the tcase back on.. .I can deadlift 250 lbs without a problem, but I suck a bench presses, besides the fact that a tcase is hella awkward and I don't have a decent floor jack... I kinda have a couple tiedown straps across the frame that's holding it off the ground now, I'll see what else I can do to make it go in. The tranny is all back together now though.

pffft.... me and ALL my friends can deadlift over 400lbs... you're puny !

well, tcase is positioned... splines are being a PITA though.. if can get them another 1/4 inch I can get the nuts on which will help... I used straps to winch it together so far, then I fired the engine up and reved it in 5th, and that smartened the splines up a bit.. II'm indoors now since a hailstorm just decided to come through and soak me and I don't have much feeling left in my fingers

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Oh, and the felpro valve cover gaskets in the kit seem to be a silicon rubber.. I've usually had pretty good success with those

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I'm a skinny fusker.. 135 lbs soaking wet... but I have good news.. all the hard parts are done, t case is bolted up.. all I have left to do is the tcase shift bracket, tranny mount bolts, front driveshaft, and filling oil... and with any luck it doesn't go boom too soon again... Once again I'm warming my fingers though!

Good to see you're not giving up on it...

These are stout and ruggid trucks... i just signed up for my 500.000 mile badge at the "High Mileage Cummins Club"

It did have 490.000 miles on it when i swapped the motor and driveline to a different body...

These motors and drivelines will outlive their trucks... that's for sure !