Re: Bad Ass Syclone goes FWD =)
Hoover's broke a sy output shaft off the transfer case. They switched to the more desireable Ty transfer case with the 32 spline output shaft. That shaft is deceivingly long and has to take a lot of twisting. The viscous kinda buffers the shock that the output shaft on the trans takes. The output shaft on the transfer case though doesn't get any "buffering". Get a Ty setup if you don't already have it. How did the planetary in there look? Couple of the Ky guys have busted that planetary. That's a beef planetary with a thrust washer on each side. The bearings are damn tough and hold everything straight. Remember too that the output shaft on the transfer case has a "scoop" on it to pick up oil to bathe the planetary. This oil slot weakens it a bit but is neccessary. If you look at the input shaft of the T-case, it is solid until you get to the tip. There is a little plastic end on it. This is what the oil goes into and then out of 2 holes that shoots the ends of the planetary. I highly recommend pulling this apart and checking everything when the trans is done to be sure none of those holes are occluded.:tup:
You'll be shocked how much residual metal sludge builds up in the ring gear that the output shaft splines into.

This crap could easily block a lube feed.