Hodakaguy M38 - Pics and Misc Thread.

[Hodakaguy]

More disassembly and inspection on the transfer case.










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[Hodakaguy]

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Main shaft gear shows some wear on the inner splines, as well as some isolated pitting on the main teeth.






Shift fork bolts wired in place





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[Hodakaguy]

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At first glance the output shaft gear and sliding gear look in pretty decent shape. A close inspection of the teeth show pitting deep enough to go through the hardened metal.








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[Hodakaguy]

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Minor pitting on both output yokes.




Pulling the seals out of the front output shaft housing.






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[Hodakaguy]

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Shift Rails show pitting where the seal rides. These will be replaced.




Shift forks








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[Hodakaguy]

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Checking clearance between the case and the shift rails. There is some slop here, although it shouldn't affect anything in operation. No allowable clearance is given for this clearance in the Army repair manual.








Lot's of parts on order. Now to get everything cleaned up and prepped for re-assembly.

More to come.

Hodakaguy

[bmorgil]

Its pretty tough using snap gauges to get the bore measured to the tolerance. Usually we allowed a min of .001" to .002" loose on all the shift rails. If the shift rails move significantly radially, it will allow the seals to leak. In general on assembly if the shaft fits the bore and moves smoothly, with out any perceivable play in the bore radially, the parts are good to go.

[Hodakaguy]

Thanks for the reply. The fit through the nose piece is pretty good (I'll have to measure) but the fit in the main case itself is pretty sloppy .025". Snap gauges aren't the best but can be pretty accurate with practice. I've seen NOS replacement cases around, not sure if any are the correct 1 1/8" shaft.

Thanks again

Tom C.

[bmorgil]

Tom, If you want to keep the original, I would see if a local machinist can put a bushing in the case. .025" clearance will leak. I agree with you, that's pretty sloppy!

[Hodakaguy]

Tom, If you want to keep the original, I would see if a local machinist can put a bushing in the case. .025" clearance will leak. I agree with you, that's pretty sloppy! If you get it machined, be sure your machinist fits any new bore to a new seal O.D. if required. I would find a seal first.

The shift rail is loose in the back of the case, where the case supports the back end of the shift rod. The seal end clearance seems pretty decent. I'll do a bit more measuring soon, I'm thinking the play in the back end may not be a deal breaker? I need some machining equipment lol

Thanks Mate.

Tom C.