While trying to set the end play on the intermediate shaft I came across what could be a potential problem. As I was putting the shims on the rear bearing cap to get end play correct I noticed that the bearing cup on the front bearing was pushing out.
This is the front bearing shown.
The problem could come when the transmission is bolted to the transfer case. The transmission case holds that bearing cup flush in the transfer case. It doesn't say anything in the TM about this.
I will come up with a fixture to hold the cup in place while I set the end play. My TM only states "no perceivable end play" in the specs and doesn't list a value.
The Tm also states to use heavy grease to hold the needle bearings in place for assembly. I opted for Vaseline, it should melt away and allow the gear oil to get right in. The lubricating holes in the intermediate gear are smaller and could be clogged for while with grease.
Gary
