Well, I've decided to keep my truck. It's gonna be chaper to keep it that it would be to sell it Anyway, I've got the drivetrain tore out with the t-case in a million pieces. First question, the idler gearset in the middle of the case has a spacer in the middle to keep the tapered roller bearings spaced properly, along with some select fit shims. My question is, does that spacer ride on needle bearings? The reason I ask is because the shaft is all tore up where the spacer rides and there's play between the spacer and the shaft. Next question: The output shaft for the rear driveshaft has some thin brass thrust washers, where the output shaft for the front driveshaft doesn't have any...did they disintegrate, or are there just none on that side? Any links to exploded views etc would be appreciated. Oh, I pulled the hood off the getrag I built 40k ago and it looks like a million bucks in there. Zero play/looseness The bellhousing is coming down next. I need a throwout bearing, pilot bearing and the ball/stud that the clutch fork pivots on---know any good sources? I think my vibration was from a worn pilot...I'll know in an hour. At least it didn't take out my tranny. Wish I could afford a clutch right now but I'll have to settle with a shined up flywheel and a new rear main. Anybody know the score on the rear main install tool? Lots of questions. Feel free to shoot me pm's with any specifics. Pics pending approval....
greg

 

didn't know something had happened, must have missed that thread... would be the ideal time for a clutch huh? oh well. do any of the local auto parts stores rent tools? the ones local to me (between the 4 of them) usually have what i need.

 

my rear main came with the install tool. Im sure someone has one laying around. I dont think i kept mine, it was just a little plastic ring. I figured if it came with it once then it would come with it again.

Ian-

 

when there is ware or some one didn't shim it snug then the sleeve falles on the shaft and bounces around.
that was the hardes part for me when i rebuilt my first and only 205!

unless it badly ware it will be just fine!

 

Hey Flash, thanks for the info. Images of shaft carnage pending approval...for now, here's the mess, along with the thrust washers in question...man there's a lot of pieces, hehe.



Rear output shaft thrust washers:



Front output shaft lack of thrush washers...




Clutch carnage pics pending as well, stay tuned....

 

I did exactly what your doning and the rattle in nutral,vibration at little or no load and t-case shifter rattle all when away!
shifter rattles was from a loose bolt tho

I rebuilt my 205 becuse of gear noise in 4wd....or when the hubs were lock in!

 

Hey Flash, yup, those are my symptoms--vib in neutral and at little or no load. Did you have to replace the shaft that the collar wore? How much pre-load goes into that setup? I've got three shims in mine...maybe .005 per, give or take. Everything else is in good shape in there, the tapered roller bearings included. I've got some pics of the shaft coming.

 

Here's the shaft and associated stuff, looks like it was wet at one point:




Here's the clutch and PP:



And the flywheel--Dave think's I've been doinh too many 3rd gear launches...I think it's got something to do with the 14 trees I pulled out this summer....note the polit bushing--almost 1/8'' play when slid onto the input shaft!!!:

 

That's just like what mine looked like. put it on the wire wheel(bench grinder) before i reinstalled it!

that pin look like that allso......mine didnt have quite as deep of a groove.........I wouldn't worry about it.still plenty of metal and it should be spinning to gether any ways!

Do you still need the blow up of the t-case........sorry it took me so long but...well .....I space it out

really thout some one would have got you the pic's by now but i will see if i can get them on here!!!!!

 

Well here's u a exploded view of the case,
http://www.danvm.com/dan/truck/specs...sfer_case.html
And it doesn't seem like there is a thrust washer on the front shaft. I dunno. I haven't ever torn into a 205 yet. Best of luck.
Aaron

 

Thanks aaronedwards82!!!!!!!!

Been trying for a hour to up load pic's form my survice manual but some thing isn't working with the up load part of this sight...........could be me but i .......any ways thats the pic that i was trying to up load! yours is way more clear!

Probably wake up in the morning to find dubble of both pic's

 

Thanks for the link aaron! I'm gonna order a small parts kit/gasket kit today. Trying to decide if I can afford a con-o clutch or not....with all the hassle in taking everything apart, I almost can't afford not to, hehe.
Greg

 

So did you throwout bearing fall out when you poled the tranny?
Mine did and i had to ruffin up the surfice w/ a center punch so the new one would stay put! Added a little high temp red lock tight too.

one of the shaft that used a caged bearing left a roller coster afect on in. spent a lot of time with a lot of emery cloth. didn't get all the bump out, but the noise in 4wd hasn't returned!

 

Naturally, we're going out of town this weekend, but I hope to be up and running by Monday or Tuesday. I run a little mobile oil-change/PM business out of this rig, so it's gotta roll...soon Thanks again for all the input, everyone

 

Sorry Yes pilot not throw out