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I determined my TC was basically new and the 3 shafts had never had the bearings set properly. It worked sweet after I set the bearings right.

Ok, not knowing how the sprag works exactly has made it's assembly to the main case difficult. The air shift ring that engages the smaller outside teeth of the sprag clutch unit can be put in backward and you will find out when you go to put the air cylinder piston on, after the case is...

Yea, I would want the air shift also but I think there will be a lot different for the front drive. Wonder if anybody has put an air shift from a T1138 on a T138 to get rid of the sprag?

That would be interesting...only change out the shafts with gears. I thought about having different gears as I took it apart. I don't think so because of the sprag clutch unit however. I think the output shaft front end drive would be entirely different (would need to compare). This...

Thanks glassk, I have read the thread and also sent a PM. At this point, I've reassembled the case using aviation form-a-gasket, which has less thickness than the gasket. That helped to tighten things up on the tapered roller bearings. To do the final preload, the cap which has a seal...

Hasn't anybody had a Rockwell transfer case apart and successfully re-installed?

We took drive shafts off while it was in the truck and ran first the tranny, then reconnected the transfer case and ran it in low and high. In high, there was noticeable play at the emergency brake/front yoke (of rear driveshaft) and a whine. At higher speed it shook the entire emergency brake...

Taking out the transfer case for output bearing replacement. Has anyone been into the Rockwell that can give me a link to a thread and maybe a few words of wisdom? Note the transfer case is the only part of my drive train that does NOT look original but has reasonably fresh brown paint...