Broken Idler Gear Tooth

[Shark Bait]

Well, I'm wondering if I may have found one of my problems. When I traveled to and from the club meeting Wednesday night I noticed a bad knocking sound in the drive train. We were guessing it might be the transmission. I thought it might be the t-case input gear. So I drained the tranny & transfer case and I took off the rear cone. The t-case input gear had not moved. It was fine. Then I pulled the side cover off the t-case and found a broken tooth on my idler gear in my Orion. Do you suppose this could be causing my knock? Anyone have a spare t-case?

 

[Rzeppa]

I have a spare 3 speed case, but it's not an Orion. Let me know if you need it. I thought Orions came with their special idler to fit the low gear on the output?

 

[Shark Bait]

They do. This Orion came with the idler gear already installed. Is your 3-speed in good shape or should I rebuild it? I think Timmbuck2 has a couple and he lives a little closer to me. I have a PM in to him.

 

[wesintl]

what was the screeching sound pulling out? brakes dragging?

 

[Shark Bait]

what was the screeching sound pulling out? brakes dragging?

No. That may be the wheel bearings are loose. I need to check that, too.

 

[powderpig]

Thats a good place to start Chris. How was the bearings at this point? if they are loose, with the chipped tooth, it could create the feeling we were getting.
I think his bearing are loose on the passenger side, only squeels like then when you turn a right hand turn. If not bearings a flexy rim that is getting close to something.

 

[Red_Chili]

Chris, that almost has to be a manufacturing defect? How could the tooth break unless foreign matter entered the case?

 

[Shark Bait]

Thats a good place to start Chris. How was the bearings at this point? if they are loose, with the chipped tooth, it could create the feeling we were getting.
I think his bearing are loose on the passenger side, only squeels like then when you turn a right hand turn. If not bearings a flexy rim that is getting close to something.

I haven't checked that yet, Robbie. I will.

Chris, that almost has to be a manufacturing defect? How could the tooth break unless foreign matter entered the case?

Foreign matter is always a possibility. I rebuilt this t-case several times trying to get the bearing pre-load right. I suppose if I had a bar jammed in there while wrenching on it, I could have buggered it up. But I thought a gear would be tough enough for that.

Meanwhile I'm going to look for a substitute t-case.

 

[Red_Chili]

Bars have many a young man ruined.

 

[treerootCO]

Call Advance and order a new idler. You are going to have a lot more work swapping in another t-case.

 

[wesintl]

I've seen the gears in my case break off like that when the idler bearings went bad and cocked the gears putting stress on the teeth til some broke off.

 

[Uncle Ben]

PM sent

 

[Shark Bait]

If anyone wants to come watch or help or drink beer, come on by. I will be pulling my Orion and, hopefully, rebuilding it and re-installing it. PM me if you need directions.

 

[Shark Bait]

Found the culprit. Why would a thrust washer do that? It's number 25 in the schematic below. It munched 3 other teeth besides the first one.

 

[Rzeppa]

They do. This Orion came with the idler gear already installed. Is your 3-speed in good shape or should I rebuild it? I think Timmbuck2 has a couple and he lives a little closer to me. I have a PM in to him.

No idea on internal condition - I bought it from the same guy that gave me the driveshafts. It's still attached to the 3 speed tranny and is pretty grimy on the outside.

 

[Shark Bait]

No idea on internal condition - I bought it from the same guy that gave me the driveshafts. It's still attached to the 3 speed tranny and is pretty grimy on the outside.

Thanks anyway, Jeff. Timm was kind enough to lend me one. Just picked it up this morning.

 

[Rezarf]

Bummer Chris-

I hope it goes together smoothy bud.



Drew

 

[Red_Chili]

Weird, you have two #25 washers in that drawing... Guess they are the same part no.?

I had a Bultaco once that munched one of the thrust washers on the small end of the con rod. Wasn't pretty. I learned how to split cases that spring. Only took me three times to get it to seal again.