Reduction Gear Wear vs. Normal

[rruge]

1996 Outback, AT, 115k

 

I am trying to decide on whether or not to buy the $133 reduction gear for my transfer case. Should I replace the gear knowing that the car probably has about another 85k miles left?

 

Reduction Gear Condition

I just pulled my Extension or Transfer case and found what appears to be wear on the inside of the "transfer clutch inner basket". However, the thrust bearing shows no signs of wear and spins freely. Here are pictures.

 

Note: all image links have been updated. See the my new posting on this thread regarding access to these images....

<image 1>

<image 2>

 

The center ring is about 3 thousandths of an inch deep or so. Even though the bearing shows no wear, I did have some transfer case work done at 15k where I experienced the transfer clutch binding issue. However, I don't believe they did anything with the thrust bearing and such.

 

The other issue with the RG is that there are grooves notched out on the side of the basket. Another picture:

<image 3>

 

These are due to the clutch discs pushing into the clutch basket. A picture of the clutch discs shows where the discs were moving off of center. Notice the clutch wear outside on the outer disc and the wear inside on the inner disc. Apparently the discs were running about 1/16" off-center; bad. The grooves are about 1/32" deep and I was thinking about filing the burrs off and reinstalling it.

 

<image 4>

 

The wierd thing is that these worn outer (left) discs actually "shrank" (or otherwise morphed) in diameter about 1/16" and do not easily slip back over the basket. These had to be pounded off.

 

Let me know if you would replace the Reduction Gear or not. I appreciate your reading all the way through this over-analysis.

 

Thanks in advance.

 

Peace,

 

Richard

[Scottbaru]

No access to your pics.

 

 

HTTP1.1 STATUS 403 Remote Access to this object forbidden This file cannot be directly accessed from a remote site, but must be linked through the Brinkster Member's site.

[sea#3]

The center ring is about 3 thousandths of an inch deep or so. Even though the bearing shows no wear, I did have some transfer case work done at 15k where I experienced the transfer clutch binding issue. However, I don't believe they did anything with the thrust bearing and such

I think(if my memory serves me right)they left out one side of the timken thrust bearing , it usually has two thrust plates on either side of the bearing and does not run directly on the gear it self, you may want to research that a little

The other issue with the RG is that there are grooves notched out on the side of the basket.

 

 

These are due to the clutch discs pushing into the clutch basket. A picture of the clutch discs shows where the discs were moving off of center. Notice the clutch wear outside on the outer disc and the wear inside on the inner disc. Apparently the discs were running about 1/16" off-center; bad. The grooves are about 1/32" deep and I was thinking about filing the burrs off and reinstalling it.

Yup that's not good

 

 

The wierd thing is that these worn outer (left) discs actually "shrank" (or otherwise morphed) in diameter about 1/16" and do not easily slip back over the basket. These had to be pounded off.

To say the least these clutches are "fubar"ed . You may have a bigger issue with the duty selenoid and / or mismatched tires

 

Let me know if you would replace the Reduction Gear or not. I appreciate your reading all the way through this over-analysis.

Yup time to replace and make sure it gets set up properly

Thanks in advance.

 

Peace,

 

Richard

 

SEA#3

[rruge]

Regarding the images discussed:

 

Go to www24.brinkster.com/richardruge then click on the image number. I have listed each image with a number.

 

Apparently Brinkster disallows direct access to the images from another web site than its own.

 

Thanks,

 

Richard

[rruge]

Real bad news. I just spoke with the guys over at 1stsubaruparts.com. Apparently there is a Service Bulletin (TSB) that says if I am changing the reduction gear, then I need to also replace "driven gear" and "pinion shaft" as a set. This will add another $420 to my $300 transfer case repair not to mention that I would have to open up the front transaxle compartment! I do not believe I have the manual for this part of the tranny (probably not a big deal).

 

Can anyone provide more information on this. The parts guy read the TSB to me and there was nothing that mentions why this is necessary.

 

I am thinking, buy the RG without DG or the PS, compare the new to the old RG, and, if there is nothing obviously different, *********eddaaboutit. Any opinions would be appreciated. Does anyone have the TSB or where could I go to get it?

 

Thanks,

 

Richard