Transfer Case Fix

[MAD_TRBO]

I have the '93 GSX Eclipse, I just recently began experiencing a leak from the transfer case. At first I thought it was the seal that goes around the yoke. So I replaced this and the leak continued and I came to find out it was the yoke itself. It appears as many of you know there is a defect in the design of the plug on the yoke. So I replaced this.

Subsequent to the repair I put the driveline back into the car, note I was careful to keep everything at only slight angles. Making sure not to break any of the boots.

When I took the car for a drive I experienced a resonance / vibration in the car. The vibration comes on around 25 - 30 mphs but no where else.

More details when I went to put the yoke back on the universal joint I could not get the bearing in far enough to replace the c-clip on one side. So i ground down the bearing just far enough to slip the c-clip back in. I am wondering if this would throw the whole thing out of balance? I didnt think so and still don't. The carrier bearings are relatively new, may 3 years.

Any ideas as to the problem and the severity. I would imagine this wobbling will eventually create problems elsewhere.

[OddRob]

you might have messed up one of the needle bearings in the yolk, they can be a pain to keep in line.

[MonoTalonAwd]

More details when I went to put the yoke back on the universal joint I could not get the bearing in far enough to replace the c-clip on one side. So i ground down the bearing just far enough to slip the c-clip back in. I am wondering if this would throw the whole thing out of balance?

I encountered the same situation when I replaced the universal joint on my Tsi. I didn't have enough clearance to put my last c-clip in. At first, I thought the size tolerances on the universal joint were off, so I began contemplating the idea of grinding down the c-clip and force it in its groove. But that didn't seem right to me.

So I disassembled the UJ from the yoke and discovered that one of the needle bearings fell inside of the "cap". They're just held up in position with grease. That's why the UJ seemed too big to fit in its place.