Dana 20 output shaft problems

[Otis Campbell]

Rebuilt my transfer case (J-shift). Everything seems fine EXCEPT I cannot get the rear output shaft correct. Once I get the flange torqued, it is very hard to turn. I've tried more shims, I've tried fewer shims and it doesn't seem to make a difference. I've tried endplay from zero to .005" before putting on the flange. Once the flange is torqued there is way too much preload. I'm reassembling without the seal to check preload. Any suggestions?

 

[Otis Campbell]

I got it…. Finally. It was a combination of speedo drive gear not all the way down and not trusting the pre tourqued flange feeling. Thinking that ain’t right when it was.