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Thanks so much Guy! Will look at my phone 8-)

Disgust as I had most all assembled ...

Just to add some cream to the cup of coffee, as I was assembling the transfer case the weekend I discovered the same bush for the front outlet, well hidden away in the casing.

So, off to making...

This is one option I am seriously considering. Brain is furiously working on other schemes and plans ...

The issue is the groove needs to exit at a very specific position on the edge of the bush so it will have to be a very specific thread and VERY course. Thanks for the advice!

Yep, I am thinking of going your way with the plans and stuff you kindly sent to me. Just putting some feelers out there, maybe someone has a set laying around.

@Mark, I had the belts donated by BMG for which I am super grateful.

The secret to make any grumpy Italian a happy Italian is excellent coffee ...

Wha hahahah. Yeah, however I have never understood any single one of the "skoner geslag" ....

Maybe if I say rotary table instead of horisontal table?

Jip, die vraag is net: "Wat nou ...?" as iets breek ... Jy weet, daai stilte wat volg en dan ...

Ek sal met hom chat en hoor.

He is not interested ... offered that I can come and cut on his milling machine, but I am too scared to work on a engineering shop's milling machine with something I have never done before.

I am taking a wild chance here. Does anyone have a 16DP gear cutter to sell or maybe lend to me? I want to get the change gears repaired areas cut into teeth.

I had a look at this @Peter Connan and my thoughts are leaning towards a horisontal table turned by hand and a vertical internal cutter lowered by hand. And lots of pills or liquids .... for the...

No your idea is good. I will give it some thought!

Now you have me really worried ...

A lot cheaper from Die Garage


https://diegarage.co.za/?s=solenoid&post_type=product

Back to assembling the gearbox.

The output shaft bearings was cleaned of grease and then oiled. I must say the seals are keeping the oil inside and I have not noticed any oil leaking from these.
...

Please let me know where I can get these C-clips. I have given up on finding a supplier.

No idea regarding the greased or not greased bearings but the Mitsubishi bearings come sealed.

https://i.postimg.cc/zXTF5bRF/Screenshot-2021-02-21-at-11-26-34.png



The bearings that I...

Thanks for this @plunger. Munch appreciated!

I have joined on that forum and will continue with your thread. Thanks again for your effort to help me. It really means a lot!

I found this very interesting thread.

How to cut an internal helical oil groove

Seems like the simplest way is by hand in a Dremel tool which will not work here as I have so little thickness...

I worked the whole day on the Pajero's transfer case so only had time to post now.

Here is the extension housing with the bush installed.

https://i.postimg.cc/LXRXBLws/IMG-20210220-164944.jpg

First off the gearobox oil quality. I do not want the grease in the bearings to dissolve into the gearbox oil. Secondly the bearings are splash lubricated by the gears so as far as our discussion...

Brain is super excited! He ran off to his books to look up for the meaning of "ruminate". I think for the next few days I will hear all about how you can use this word in all the various possible...

The first bearing to be installed is the one on the input shaft. It is important to understand that you will need to install the bearing onto the shaft, then push it from the inside of the casing...

Rightey'ho ... homework is done so onto reassembling.

With the gearbox casing cleaned, painted and looking like a new six pence, it is time to install the shafts.

First will be the bottom...

One other thing I need to get in place is a summary of all the parts required. I will update the links as I progress.

There are a number of items to have in hand before you can start reassembling...

For continuation's sake I will duplicate previous posts here. So my apologies if you have read some of these posts before, but I think it will assist those of you who are using this thread to service...

That was my original idea. Issue is how to you start the slot as it only comes to the edge on one leg. Secondly how to you keep it on track. You either need an external guide or eyes on a line.

Yep, that is the last resort way I will do it as I know it will work. How good is the question. Been sitting this afternoon thinking of to do it and it is not that simple ... But ... I have Brain on...

This is the way to do it if you have a lathe ...


https://youtu.be/TJH2q5ylJXM

Sketch this for me if you do not mind.

Nicely machine by hand it will have to be ... aziko lathe apha

Just as a reminder this is what I need to cut ...
...

Great minds think alike. This is exactly what I am planning to do.

https://i.postimg.cc/VNRCrDBZ/White-metal-groove-scraper.jpg

This is very interesting. Thanks for sharing this information @Peter Connan!