t-90 rebuild

i seem to have succesfully rebuilt my first tranny. only thing im concerned about is the clutch hub moving a little stiff. one synchro seemed a little tight. hope its o.k. we'll find out soon enough and if not,i'll just do it again.

 

Congrats!
Do you have the transfer case input gear on and torqued? That generally pulls the output shaft (mainshaft) back and increases the clearances between the 3rd gear blocking ring and input gear. Sometimes it will effect 2nd gear as well as the input gear is not pushing so hard against the 2/3 sychronizer assembly and it pulls the output shaft fully against the output bearing.

 

not yet, tranny is still on the bench,i should get it bolted up to the t.c. today. what is the torque spec? also, new kit had a different type nut to hold the t.c. input gear on. old one has the slots in the end to put a cotter pin in, new one just has a plastic ring in it. think i like the old style better. also have what looks like a thrust washer about the size of the main bearing,i'm pretty sure it goes between the main bearing and t.c. i cant find it in any drawings yet. by the way what do i do with the rest of these extra parts. (just kidding)

 

From your description that thrust washer sounds like the slinger that goes between the input gear and the input bearing.....
There is a spacer that goes between the mainshaft bearing and transfer case input gear but it is thick, about 3/8" thick or thereabouts but it's not as large as the bearing, it's more like a ring probably with a wall thickness of 3/8"-1/2" or so.

There are two different thread diameters and pitches on the mainshafts that hold the gear in place on T-90's. One is larger and finer thread iirc and that uses the nut with the cotter pin slots. The smaller coarser threaded shaft uses the self locking nut.

 

No problem reusing the castellated nut with a new cotter key. The insert nut is included because you are not supposed to reuse them, so if you had that type, you'd need a new one.

Note there are often lots of extra parts in the small parts kit, just to make sure that the kit covers all the possible applications. I would recommend buying an inexpensive vernier caliper and measuring all the new parts you install, while comparing to the old parts. Careful disassembly, keeping all the old parts grouped together and labeled with their origin, will help to make sure you use the right parts in the right location.