Sounds like trouble

Are you thinking they actually made note of the gear numbers and would still have that information on file to pull for you all this time later? Seems like a real long shot. That isn't typically a part of routine overhaul procedure. I guess you could always ask them for it and see what they say. I know the removal task seems daunting to you, but I really don't see an alternative if you want to solve this mystery.
 
I guess im looking for confirmation that this could be the issue, not necessarily a look into their archives. When I asked the guy at the gear shop he said a t-19 is a t-19 and a Dana 300 is a Dana 300. Ill pull the thing off if I gotta, but yeah yer right I dont wanna
 
What they're saying is not totally correct. Its an indisputable fact that there are two different gear pitch angles between early versus later d20's. If the t-19 was donated from a pre-'73 Scout originally mated to an early d20, then there could easily be a mismatch between it and your d300 which was only offered in the 1980 model year scouts...end of production days. It would be the same thing as mating it with a later d20...gear pitch mismatch.
 
Dude I'm getting excited. So what ur sayin makes perfect sense. The Scout is a 72 so if that's the original t19 it would have been mated to the earlier d20. Now it's absolutely possible that it's mated up to the d300 with the "newer" pitch. If that's the issue would I b able to swap gears to make these two gear boxes work together?
 
The 300 would only have the later gear pitch, as like I said it was only offered for one year...the last year of Scout production. The output gear on the t-19 is the only variable that can be altered with a different output gear to match whatever t-case is attached.
 
Alright its out. So the gear thats on the back of the transmission doesnt have any numbers that I can read. It looks like the one on the right in the above photo that michael posted. Do I need to remove the gear to read the numbers?
 
From what I can see of your vid,and mm's pics,yes it appears that the t-19 gear #'s are on the opposite side,facing the front of the vehicle?Jeff
 
I looked front, back, top, and bottom with and without a light and no numbers. Is there any way to tell by tooth count or something like that? Maybe I need to take something apart?

I did notice a distinct shiny ring on the bull gear similar to the one in the picture that michael posted, but even more obvious. Also there is what seems to b a perfect imprint of the output shaft from the t-19 on the gear in the transfercase. When I put this whole thing together a year ago, or whatever it was, I did use a shim but maybe it wasnt the right one? Maybe it needs to be thicker? The transfercase is in the shop now so any bearing preload issue should get resolved but maybe you guys can sell me the the good and proper gasket.
 
The number is on the transfer case side of the gear the correct # for the Scout t19 with Dana 300 is. 1l17 300811 it is stamped on the inner gear
 
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There ya go 'ibramblin" take the small,outer gear off an see what the # is on the inner gear.it's prolly not the d-300 gear to be used? At least now you know where the # is,if it was like that when the p.o. Had it,then thats prolly the problem.? Jeff
 
The bull geer is one peice if it is still on the transmission looking at it the number is on the the inner part of the geer clossest to the nut I tried to post a pic but cant figure how to do it with this ipad from what I can tell on you video there is no number on that geer
 
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That bull geer on youre transmission looks like the
correct one. The bull geer for the Dana 20 is more like the one shown on page two but with the six spline for the transmission shaft.
The inner geer is smaller diametor than the 300 bull geer.
 
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This noise that I describe as similar to the noise you get when you try to change gears without pressing the clutch has been goin on ever since I bought this truck. The previous owner said the noise was there the whole time he owned it too. He wasnt the one that did all the mods and he didnt own it very long so I believe him. Mayben has created a couple of posts that point out the "spacer" or "shim" quality of the gasket that goes between the tranny and the transfer case. Maybe the gaskets that were used previously were not the right ones (not thick enough) or the bolts were overtightended and crushed the gasket?? Is there a proper torque for those bolts? I think I just remember crancking on it.... Also ive actually pulled the transmission completely out of the truck again and found some play in the front shaft- not in and out, but more up and down side to side play... Is that normal? The output shaft is solid. The transmission is gonna get torn down so we can see if theres internal shananagins either way
 
Does it do it when you shift. Or in any gear all the time. I would think if you pulled rear driveline and it quit it would be in rearend,driveshaft out of balance,out of phase,also check output shaft on transfercase for exessive play.
 
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Its most noticable at higher speeds but pretty much does it all speeds. It seems like when the drivetrain is under load its much quieter (exceleration or downshifting), but if I feather the gas or on a light downhill descent its most noticable... And if the clutch is in too. Ive tried every combo of front/rear drive shaft on/off, 4wd/2wd and the only one that doesnt make the noise is 2wd no rear shaft and 4wd no front or rear shaft. Im not sure if this tells me anything though since its so far from normal operating conditions- no load at all on any of the gears, they are free to spin. I do know that my driveline needs some love ( its at a crazy angle- front and back0 but the shafts have been completely rebuilt.
The output shaft of the transfer case seemed pretty solid. The input shaft on the tranny however seemed a little floppy. I dont know how much if any flop is acceptable??
What about the gasket idea? Do you think I May have used the wrong gasket or over tightened the bolts and didnt leave enouch clearance ?
 
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To me this eliminates the transmission and transfer case I suspect the rear end jack it up and pull the weels and drums off and check outer axle berring play.on a older Scout those are grease packed bearings you might have one on its way out. Also check pinion play or roughness. If every thing checks out good remove cover check for abnormal wear on ring and pinion.put pry bar on ring gear and check for carrior bearing wear
 
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