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Posted by Will (in IL) on Friday, March 06, 2009 at 21:38:56 :
A few Pictures of the weeks work at my WEB site, but good progress today.
The inside of the new tranny looked good, and felt smooth and tight. I did discover that it's rear housing was not machined correctly, and left a gap between the rear seal and the yoke on the passenger side, thus explaining why the old seal looked oddly worn. So I pulled the rear tail housing off the old tranny and installed it. It was much better, but not perfect, tighter on the bottom, and looser on the top, but no gap.
With Jason's help (son-in-law #2), I got the transfercase and transmission both installed back in the truck. Filled both with oil, and did a little fine tuning of the clutch. Sure could use more travel in the slave cylinder, but all is good, just not a lot of room for misadjustment.