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I'll just say this. Trailering a hmmwv around will get old fast. They are too wide and in some cases too heavy for a normal bumper pull trailer. So then you are stuck using a gooseneck or flat deck equipment trailer. Then your normal half ton truck is out of the question as a tow vehicle...
Is that tc38 too big? Outputs in the wrong place?
I'd rather have that transfer case over the deuce transfer case any day. Assuming it fits in the space your wanting to shove it in.
You must have got a bad one. I have torqued on mine pretty hard and never had this issue. Don't get me wrong I'm not a fan of new star but this particular part isn't absolutely horrible.
I had a few new star seals that didn't really want to slide over the spindle. Had to hit the inside of it with a file. I have had them make the outer bearing hot because they were warped. So far I haven't had the key tab break off.
Unfortunately, new star is about the only option with...
Yall are seriously over thinking how to clean the axle housing. Just take a piece of pvc pipe and push some paper towels through each end of the axle tube. Then wipe out what remains in the center section. If you miss a fine metal shaving or 2 who cares.
As annoying as it may be your best bet is to remember to install the plug before mudding and remove it when your done. Though with your use of the truck I'd say leaving the bellhousing plug in is way better than forgetting to put it in.
There's a plunger under that triangular cover. I remember someone posted that they put it in backwards and that caused the air pack to act up. God I'm trying to remember what thread that was.