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Well getting the air shift back in wasn't as hard as I thought it would be. I went for a 10 mile drive and it functioned fine, shifted on the fly, didn't pop out of gear, no noise. No problems. I did stop and feel the case, the bearing ends felt hot to the touch, couldn't keep my hand on it...

Heath, as a project manager at a steam turbine repair shop, we always avoided welding castings, even with a high nickel content rod, preheat and post heat, it might not work. Metal stitching is the best repair, but not an economical option for me. And not to mention that case is already...

Ok, so the difference is not in the gears themselves, but the shaft they're on. I follow now. The remaining air shift parts I'm left with that could build one transfer case are not pretty, as you may recall the broken input shaft bearing, busted case, and also other items are worn like the yokes...

Thanks for that info! From that thread, I found this, and I was wondering if you could clarify it some more? I think I have all the parts left over from the two air shifts to convert my sprag to a spare air shift, but I'm not sure what you mean by the "remove 33 tooth gear from both rear output...

It was a long weekend. I'm whooped. I finished rebuilding the air shift during the week so this weekend I removed the sprag unit. It wasn't too bad, just about 8 hours needed, from removing the hard top to dragging the case out from under the truck with my civi truck and my surplus rigging...

I had to tackle a bunch of other things tonight but I got the gears in the good case at least. Man this thing is kicking my butt. So I have gaskets cut out of 1/32" thick gasket material and I filed down the split lines with a file then a knife sharpening stone. Should I still put a coating of...

Wow, that sounds easy now. Sometimes you just need to stop and take a break. Seems pretty obvious now the way you described it. Thanks! I should be able to start on reassembly tonight. I got new input/output seals from rock auto for $7 eash, I did some research and found people using the...

It's been a little over a year and things are a bit rustier than I left them, but I bought a house and moved everything and did a lot of work to the house and other mechanical projects so now it's back to this. Tonight I started taking apart the other transfercase with the broken casting, as...

Beautiful! The gears look perfect, despite all those mashed up pieces.

I'm getting everything from case with the shifting problem cleaned up and making gaskets as I go. You can see 2 pictures of the mystery fun parts that were in the bottom of the transfer case when I opened it up next to a quarter for reference. My plan is to reuse everything out of the case I...

^Thanks!!! I'll take lots of pictures this weekend as I go.

Ok, so I tore down the air shift case with the bad internals. I found 30% of a bearing race and a beat up ball bearing, so I assume the previous owner pulled out the other parts. I can't see where the bearing came from, so it must be from inside the shifting mechanism. The case did have...

No lever on the sprag. The air lock is a manual already, air actuated, you want to convert it to mechanical engagement. I would search the forum to see if it has been done.

Gotcha, I thought I could see a pinion brake kind of in your avatar picture. Going from air shift to sprag is really unheard of. Everyone would rather have an air shift. Reliable engagement at the flip of a switch. The sprag engages when it senses slipping unless it is worn or out of adjustment.

If you're using stock brakes then you need to keep that air compressor. The air pack that acts as the brake booster is supplied with air by the compressor. It would be cheaper and A LOT less work to replace just the air compressor. There is plenty of room above the alternator on the passenger...

I would sell you mine but you're kind of far away! Why do you want to switch to the sprag? From my research, the only difference is one of the mounts uses studs and not bolts or something of that sort, but for the most part they are a direct swap. I started tearing down one of the airshift...

In my quest for the conversion from the sprag to the air shift, I have acquired two air shift cases with their own unique problems at a fair price. In the pictures, you'll see that the one on the left has a broken mount. I assume this was broken when the truck that it was in was rear ended and...