D300 & Teralow kit

Mudrat

OK, So I finally have a week off and got around to getting the Heart of the Beast running again (see engine thread. The new Dizzy fixed the 50* timing problem :lo1l: ). So I decided to take the TeraLow kit I've had on the shelf for over a year and throw it in the spare D300 gear box. Some minor SNAFU's but nothing insurmountable . . . until I dropped in the center gear section and it doesn't fit?? The input and output shafts and gearing went together as designed and planned. It was a PITA to get 70+ pounds of T-case set up square in the press to put the bearings on, but again no big deal. Back on the bench, got the needle bearings installed in the idler gear and dropped it in the case, but it's about 3/8" off from falling into place to insert the idler shaft?? The gears mesh and everything turns smoothly and have GENEROUSLY used assembly lube to help - to no avail. End play for the shafts is by the TSM, but the idler gear just won't go down that last 3/8ths so I can button this thing up? A 2.5 pound dead blow hammer doesn't work by the way :oops: Taking the bearing caps off the front output shaft and trying to move it side ways didn't work either. It looks like there is room between the teeth on both sides (input/output gears) but it just won't go :-| Anybody have suggestions?

cjmike67

Soory made my reply a new post under TERALO :razz:

jeepsr4ever

Did you grind the case...you do know the case needs to be ground for the large gear.

Mudrat

jeepsr4ever wrote
Did you grind the case...you do know the case needs to be ground for the large gear.

Yup, but not that much, just the notch they said to carve out.

Got it figured out though ...

After beating myself up, I took the T-case all the way back down to parade rest, pulled the gear clusters apart, and checked all the shims etc...

Then I put the danged thing back together after everything checked SAT. Since the instructions were LAME on how to install the shifting rods I did a net search and found NOTHING for the Teralow kit, but found some GOOD info from some guy that did a LOMAX kit.

See the lower left shift rail ... ?

Of all things I had installed the rear shift rod upside down (180* out) and the cut out for the larger gear was keeping it from falling in place :oops:

Thinking about it, the case is assembled upside down, but the DWGs are all right side up. 111!!! (ok so that's a lame excuse, but that's my story and I'm sticking to it! :wink: )

Oh well, it's back together and has the first coat of primer on it :t: