Looking for opinions on what to do with my transfer case.
I have an MUA5 transfer case (including Revo gear change) from a '91 Trooper with 3.4L Swap. The transfer case ran low on fluid and started making terrible noises, so I replaced it with another transmission/t-case, planning to either change the Revo gears over or rebuild the original T-case. Unfortunately, the seal between the transmission and t-case is leaking (I have tried to vent the transmission - still leaking into T-case), emptying the transmission and overfilling the T-Case. I now have two bad units and need to get it fixed.
I need some parts and advice:
1) I have pulled apart the original T-case - the needle bearing on the T-case input shaft (main shaft) were the primary issue. Here is a picture of the needle bearings - the black debris is the bearing housing, and the bearings show signs of heat. The bearings seemed to be contained in the assembly until I took it apart.
2) There is scoring on the bearing collar from the needle bearings - further proof of heat/damage - I strongly suspect this needs to be replaced.
3) There is a divot in the bottom of the bearing collar from the ball there - is this normal? What does the ball do?
4) The idler shaft bearing on the forward side seems to have minimal side to side play (.004") (perpendicular to the shaft), but has ~.040" end play (parallel to the shaft) - I think this bearing needs to be replaced.
5) The idler shaft bearing on the rear side (the sealed bearing) has a small indentation on the seal surface:
6) There are some dents in the face of the hi-low synchronizer assembly - are these a concern?
7) As long as I have things torn down this far, I would replace all the seals (front t-case input, rear output, front output and probably front input). Should I also replace any of the other bearings?
Newer (Leaky) Transmission
1) Leaks fluid from Transmission to transfer case - transfer case input shaft seal needs to be replaced (complete tear down of transfer case)
2) When I put this unit in, the front output shaft leaked as well and I replaced it. I am concerned about its condition after having issues with these two seals. (Some of this may be decided if/when I tear this unit down).
3) Would move the Revo gears over to this transfer case if I decide to use it.
A) Rebuild the original transmission with new parts as needed put into Trooper, maybe replace seals in newer transmission and sell it.
B) Rebuild the original transmission with parts from the newer transmission as needed - then figure out what to do with the remaining parts
C) Replace seals in newer transmission, move Revo gears over - then figure out what to do with the remaining parts.
Any thoughts about any of these plans?