Hi folks, looking for some advice as I wait for the RC support guys to get back to me.

I've got my transfer case split and pulled the main shaft out. To my dismay I discovered that the large gear on mine transfer case won't fit on the RC SYE as the shaft diameters are significantly different. The pilot race on the end of the shaft is the same, and positionally everything else is the same, except for the gear.

 

It seems like 90-92 had some special differences seemingly not advertised anywhere. They have a long snout output for the slip, they're also running 1/2" chain and smaller journal for the gear sprockets.



I'm thinking that I have a few options:

1) replace the seals and chain and go back to stock

2) swap out the entire unit with a newer one (21 spline I think) and install the sye on that

3) machine the RC main shaft to accept the stock gear sprocket and replace the chain, and probably replace the speedo sensor so the new shaft / speedo drive align.

4) replace the stock sprocket gear, counter shaft gear and chain with a heavier one (need advice on this), install the sye



I'm leaning toward option 4 as I end up with a heavier duty NP231 and SYE but its going to be pricy unless I can find a junk yard TC.



Thoughts?

 

I forget what year but the needle bearings in the gear were eliminated. When I installed the SYE in my 88 I had to press out the needle bearings from the gear. My SYE was an Advance Adapters and that info was included in the instructions. I just pressed the gear on the shaft and the shaft pushed out the needle bearings (per instructions).

 

96- use the needle bearings; they were deleted per New Venture Gear's redesign for 97+. Just pop the cages out and the sprockets should slide on perfectly. Some SYE kits mention this in the instructions, and some do not.