On one occasion, I noticed one of the roll pins was slipping out and I pounded it back in. This time, the pin closest to the transfer case was out so far that it ground itself into the aluminum casting. It didn't cause permanent damage, but the fact remains that I didn't catch it in time to prevent it from happening. Is this a fluke, or is it a regular occurrence? This could have been a catastrophic failure, had I not caught it when I did. The only reason I caught it was because when I was changing oil, and was greasing it, I was hunting for a grease fitting on the drive shaft.

Yesterday, I had to pound the roll pin in that is closest to the transfer case, and also the one toward the rear yoke. Has anyone done something to prevent this from happening again? Mine has just under 1000 miles on it and under 200 hours, if that means anything.

I'm honestly, considering a hose clamp or something around the pins, just to retain them.

 

Not a fluke. Common problem on some machines with this style gear case to have roll pins work out and carve deep gashes in the gear case housing. Some even all the way through. Some people have resorted to using bolts and nuts to remedy this.

 

Dog gone! What kind of labor hours are in replacing the case? If the metal is cleaned, then JB Weld would probably do a fine job.

 

I'd certainly try jb weld or some other good epoxy if the case isn't that bad before I had to resort to changing out gear cases.I'm sure many people have done the same thing.

 

that's a pretty deep groove in your picture. Mine isn't that deep, but I'm thankful for it.

Thanks again.

I used JB weld on an aluminum lower transmission case that developed a leak in a lawn tractor a couple years ago and it's still doing fine. I run it twice per week and it's always fluctuating temperature.

 

Ditto on JB Weld or epoxy and keep an eye on it for leaks. Replace all those stupid pins with a bolt/nylock nut. Always done that on my rides and never had any issues.