The Frankenjeep

[51 CJ3]

Given the amount of time I had invested in replacing the bushing in the transfer case output shaft and lack of progress because of it… I chose to order a new shaft. It came with a new bushing installed but only measures 0.622. The front output shaft slides in with just a hint of dragging through the bushing. I ordered a 0.628 reamer this morning but now I wonder if there a spec for the difference between the bushing ID and the front shaft OD?

[bmorgil]

The shaft O.D. should be .625". The bushing clearance spec is .0017" to .005", and .005" is loose and considered worn out. The bushing by design has a range of .0017" to .0035". I think .003" is as far as I would like on a new one. It will be really hard to measure the bore exactly without a plug gauge. If it fits together and turns smoothly without any wobble, that's as good as you can do without being dead sure on the I.D. with a plug gauge. If it fits together and the shaft is .625" but its a little tight, you may want to polish the bushing. A new reamer may cut a little oversize. It might just be a poor reaming cut. A bit of polishing with #400 emery cloth might do it. I bet its good.