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Thanks for the pics and heads-up, Greg! SAFETY FIRST!
And for the ones who prefer to better "RTM" (read the manual) before relying too much on their experience and memory.... here it is, well explained: TM 9-2320-361-20 pages 9-19 & 9-20.
According to the parts book and UOCs, the part number for the propeller shaft assembly (TC-to-fwd rear axle) only changes depending on the wheelbase and if it was made by DANA or ROCKWELL.
No changes between V; D & Z-models.
... which makes me think that the T-case always remained in the same...
A rusted/pitted worm shaft will eat our precious "ÿellow metal" (AKA brass gear) much faster than any wrong gear oil.
For a winch that is used once every 10 years - eventually pull out a stump, or do a 10 yard-self-recovery - it would be much better to have the gear case completely filled with...
I don't think its just rust... If it's knocking loud you have gear(s) with missing teeth - normally it's 5th gear, or 5th counter gear - or both.
Put the TC in neutral; push the clutch pedal down and hold it down with a board stuck between pad and drivers seat. Then turn the gears and inspect...
Well, yes... de nada... (I have plenty of loose parts laying around to play with; 6.2's as well as civi and mil 6.5's.)
I'm not sure what exactly RWH was referring to... and I know he knows!
All I can say with absolute certainty is this: The actual bolt pattern for all model exhaust...
Yes.
Maybe yes, although it will be a "narrow fit", at least. But first you will have to fab a custom mount for the turbo assembly itself. Also need to replace the stock intake elbow on the compressor side with something much shorter (lesser radius).
Why? The military 6.5L turbo stock exhaust...
I guess Spicer put that pin there for one reason: They sure didn't want that sleeve to be able to rotate on the shaft!
The TM says the inner sleeve diameter should be 1.7495" to 1.7500", and the shaft diameter 1.7500" to 1.7505", both areas marked as "none", for wear limit. That means a zero...
I know that the manuals don't mention it, but that "little metal particle" you found is actually a locating pin that goes into that hole you saw in the 5th-gear sleeve. It is there to prevent the sleeve from rotating on the shaft. The head of the pin goes to the inside of the sleeve, stuck in...
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