d20 popping out of gear w/video

[m_m70]

Lots of info posted on this I know. I have posted video at this link and need feedback.
My rebuilt T-style t-case has been giving me fits since I installed it last year.
The typical popping out of 2 high under acceleration or steady uphill ride.
Installed adjustable detent balls and springs which helped a little and now its back at it. I actually adjusted it to where it was VERY difficult to get into neutral. There is no end-play in the output shaft and checked torque. All good there. Finally drained and pulled inspection plate and took a video of what seems to me to be excessive play on the shift fork and gear.
Take a look and let me know what you all think. I know the quality is not that great but it was the best I could do on my back in a dark garage%).
See videos here. taken with t-case in neutral and in 2-high.

https://www.youtube.com/watch?v=ih8UuLQ-ebc
https://www.youtube.com/watch?v=UY-AoDPat1s
https://www.youtube.com/watch?v=jSkVEzosLyU

 

[Viperwolf1]

That shift fork and probably also the rear sliding gear is worn out. This is what happens when a bungee cord or something similar is used to hold the lever in gear.

 

[m_m70]

Thanks Phil,
Thought that was the case. So basically I'm kind of hosed because those items aren't part of any rebuild kit I've seen.
Guess I could by a rebuilt unit from one of the vendors (Jeffs and Toms both carry them) but I would be concerned of getting one in the same shape.

 

[Viperwolf1]

I've picked up a lot of parts D20s. I'm leaving CO tomorrow and could swing by my storage and pickup some spare parts to bring out to CA. Is that a T or J?

 

[m_m70]

T-shift. what part of CA are you going to be in?

 

[Viperwolf1]

T-shift. what part of CA are you going to be in?

Sacramento.

 

[m_m70]

If you have the parts I need in good shape let me know how much you want for them and I can figure out how to get them.
Thanks!

 

[Viperwolf1]

If you have the parts I need in good shape let me know how much you want for them and I can figure out how to get them.
Thanks!

I can let you have them but if you run across a single wheel like this I sure could use it. http://sfbay.craigslist.org/eby/wto/5346156949.html

 

[m_m70]

I will check if it's still available.

Thanks!

 

[Dirt Rider]

So what would be the good or new thickness of the shift forks?

Tim

 

[mnido]

Can you buy new forks ??

 

[mattt]

Can you buy new forks ??

I'm pretty sure Jack O'Brien sells new/refurb to factory spec shift forks. When I talked to him years ago, he suggested to not throw away any used shift fork as he would recondition it to spec. Jack is the same guy that makes Jeep Eater D20 low range gear set.

 

[Viperwolf1]

So what would be the good or new thickness of the shift forks?

Tim

I don't remember that measurement but there should only be .020"-.030" clearance between the fork and gear.

 

[70_Steve]

I'm pretty sure Jack O'Brien sells new/refurb to factory spec shift forks. When I talked to him years ago...

O'Briens 4 Wheel West
1302 Hidden Ct,
Roseville, CA 95661
(916) 773-3278

No web site.

Very nice guy, but... he likes to talk...

 

[Dirt Rider]

I don't remember that measurement but there should only be .020"-.030" clearance between the fork and gear.

Thanks for the info. I just went to the shop and checked mine. The front was .016 on one side and .017 on the other. The rear was .022 it also was a little tighter on one side then the other. I think maybe I will swap the forks when I put it back together.

 

[Viperwolf1]

If you have the parts I need in good shape let me know how much you want for them and I can figure out how to get them.
Thanks!

I got a very nice gear and fork. PM me and we can workout the details.

 

[cs_88]

Very nice guy, but... he likes to talk...

That's affirmative.