Need a little order of assembly help here guys......

[Doppleganger]

These little PITA's are known as synchro struts and keys. They are part of the innards of a transfer case. I am convinced they were designed by satan. There is no place that shows (in useful resolution or detail) how these rings and keys install. I cannot believe no one here has never done these.

From what I understand, the rings act like springs to keep the keys pushed 'out', so I am ARSE-summing they go under the keys. But WTF does the hook attach to to begin with? These were removed / missing when I got the truck, so I had nothing to go on to begin with.

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[DoubleDingo]

These little PITA's are known as synchro struts and keys. They are part of the innards of a transfer case. I am convinced they were designed by satan. There is no place that shows (in useful resolution or detail) how these rings and keys install. I cannot believe no one here has never done these.

From what I understand, the rings act like springs to keep the keys pushed 'out', so I am ARSE-summing they go under the keys. But WTF does the hook attach to to begin with? These were removed / missing when I got the truck, so I had nothing to go on to begin with.

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I did something similar to these on my 3 speed rebuild, but I cannot recall how it went together. Maybe look up a 3 speed or 4 speed rebuild video to see if they show it?

 

[Doppleganger]

I've looked at everything - they 'show' it but their hands are either in the way or the camera is across the shop and you cant see it anyways. Someone asked a similar question on a K5 site...AND POSTED PICS! But the post was over 10 yrs ago so the pics were all gone.

This seems to be a common question - cant believe no one has made a clear diagram or explanation.

 

[DoubleDingo]

Look at the 14:39-ish mark.... Not a transfer case, but may give you some insight...

https://www.youtube.com/watch?v=yOmybVKq5-w

 

[bucket]

I've looked at everything - they 'show' it but their hands are either in the way or the camera is across the shop and you cant see it anyways. Someone asked a similar question on a K5 site...AND POSTED PICS! But the post was over 10 yrs ago so the pics were all gone.

This seems to be a common question - cant believe no one has made a clear diagram or explanation.

I've heard so many people over the years say that going through a 208 is simple and that anyone could do it. However, I've always been skeptical, lol. I've always just taken them to the folks that do my trans rebuilds... a decision I'm not regretting after seeing your questions you have posted.

When you get yours all figured out, any chance you would be willing to do a nice informative writeup?

 

[Doppleganger]

I've heard so many people over the years say that going through a 208 is simple and that anyone could do it. However, I've always been skeptical, lol. I've always just taken them to the folks that do my trans rebuilds... a decision I'm not regretting after seeing your questions you have posted.

When you get yours all figured out, any chance you would be willing to do a nice informative writeup?

I would love to.....if I ever get that far. I PM'd a couple guys that did fairly good vids of the tear down/re-assembly that they had good stuff, but like most who know it all, they took for granted the details and didn't esplain them.

And fwiw....I did go to a couple transmission shops and they gave me the "we just get a reman unit" shpiel. At $1700 vs $200 me doing it...wasn't hard to at least give it a try.

Biggest issues I've had was missing parts and a cobbled assembly that wasn't right either. No way to know what it was supposed to look like.

 

[Goldie Driver]

If any of these help, I will take more.

From a 82 FSM.

20 is the synchro key and 21 the synchro hub. 22 is the synchro hub snap ring.

 

[Doppleganger]

Look at the 14:39-ish mark.... Not a transfer case, but may give you some insight...

https://www.youtube.com/watch?v=yOmybVKq5-w

Thanks dude - that does help. I'm guessing the hook on the spring is just to add tension and not to hook into anything. My keys are different shape but will give that a shot to see if it fits.

 

[Doppleganger]

Ok...for posterity and future generations sake , since no one in the history of the world has done this before, I believe this is how the springs go in. I had it this way once but didn't think it was right - but @DoubleDingo's video (IMO) confirmed this is how they go. The brass sync ring also fits like it should with them this way.

(fwiw....those are not scuffs on the nose of the shaft....its grease).

 

[idahovette]

@Doppleganger that's the way they go in a Muncie M20-21-22. Just to tension the keys......you done GOOD!!!!!!!

 

[Doppleganger]

Even a blind squirrel finds a nut sometimes.

 

[DoubleDingo]

Glad I could help in an indirect way