When I put the washers on my linkage it allowed me to keep the truck in two wheel drive and to use 4 wheel drive low. I did sometimes have trouble keeping the box in 4 hi. But this was only when I was torqueing on real hard.
This is not a permanent fix but it does allow you to keep the truck in 2wd when going down the road as well as use 4 wheel drive when needed. It can be a bit of a bugger putting a washer on the linkage inside of the case. But it can be done. This was the first time I had ever opened a transfer case and it really isnt all that complicated. Just be sure you put everything back together the same way you took it apart. Also be sure to clean any metal shavings out of the case.

Ultimately I found a deal on another newer transfer case and traded up. But my old case was still working and gave very little problems when in 2wd.

This did not completely solve the problem in 4 wheel drive, but I could use it when I got myself into a pickle

 

Well gonecrazyi this is my first transfer case tear-down also. And I'm not going to make any mistakes, I got my father in law coming over to give me a hand and I'm taking my wifes $300.00 camara out into the barn to take pics of the t-case every step. Just incase either of us forget...not like that would ever happen. As for the washers part, I fiqured I'd play it by year. I do appreciate info you posted earlyier in the thread, especially the t-case bing simple part.


Beersy50

 

I went to ace to get washers, I found ones that were fairly tight on the shaft. I used stainless on the inside and cheap steel ones on the outside. I figured I didnt know how long I would be driving on it until I found another one and I didn't want it to rust.

Depending on how bad your play is, I put two stainless on the inside and a single steel on the outside. You also have to remove the shifting shaft completely in order to put a washer on the outside.

 

Well, My problem was exactly the same as gonecrazyi's and chris1066's. Here is what I did:


You can see how the pin going into the cam was bearly catching the cam



First I made my own bushing, similar to chris1066's idea if I understood right. I'm doing this on a budget of about....A buck, Thats why I did every thing the way I did. And I need this truck.



Then I put some sheetmetal shims between the left side of the cam and the housing. I couldn't get a washer in there with out some serious grinding. But I stole that idea from gonecrazyi.


I then removed the pin that the came rode on from the shift fork and taped it with a 5/16 coarse thread tap



I went to lowes and bought a grade a allen screw that was an 11/2 inches long (I think it was that long) and thread it throught the cam and into the shift fork, don't forget the bushing that was on the factory pin.


After thightening down the allen screw I put a 5/16 nut on the end of it, like a jamb nut. A side note: I did use locktite on both the screw and the nut.


Here's the final pic before final assembly, here you can see all of it together. This hole process cost me about $10 between the bolt and silicone gasket maker to put the transfer case together. As for how hard it was...well it was pretty simple actually. It was about 2 hours by myself getting the case out and in my backyard none the less. Thanks for the info from all of you guys that posted and e-mailed back and forth. I hope this reply will help some one else.