Prep work for bushings - advise

[halo]

Hopefully someone can point me in the right direction.....

Had to rebuild the aluminum transfer case on my Ford due to a broken shift fork - fragged the internals. Problem is, the aluminum case ovals out over time where the shift fork rod goes which means a lot of play and a repeat tear down.

There are machine shops that enlarge the shift fork rod holes and press bronze bushings in place to eliminate the problem. They also charge several hundred for the honor.

I'm a hands on and would like to do this myself. I have a drill press and have been looking for a decent milling machine for the home garage.

Can this be done or is it out of the range of a do it yourselfer? I've tried the cheap route with HF and seeing tools break/not work drives me insane. Any advise on what I need/where to buy?

Thanks

 

[larry_g]

The problem you have with a fix like that is to locate the center of the factory hole and then bore the new hole concentric with where the factory hole was. With the egged hole you have is that drill will want to follow the path of least resistance and a hole produced with a drill bit in a drill press will not be on center. What you need is a rigid machine (mill or jig bore) that will guide a boring bar through the hole while maintaining center. Then it is a simple task to buy or make a bushing.

Here is also why your location is important cuz your neighbor may step up and offer to help.

lg
no neat sig line

 

[theoldwizard1]

The problem you have with a fix like that is to locate the center of the factory hole and then bore the new hole concentric with where the factory hole was.

This is MUCH more difficult than it sounds !

The hole center is likely specified as a distance off of another hole center.

The reason those shops get big bucks is more locating the hole, not drilling the hole !

 

[crewchief888]

i'd be looking for another xfer case

 

[gorilla]

The last time I bought new Bridgport mill it was $16,000.00 add about another $1,000.00 for tooling to be able to do the job and a machinist salary at about $25.00 an hour and that $300.00 to do the job really isn't out of line.

 

[Agent1320]

Weld the hole shut, drill a new hole, tap in a bronze bushing. I've done it in several transmissions and t-cases. No fancy lathes or mills needed. A welder to weld up the hole, a center punch to mark the center of the hole to be drilled, a hand drill to do what drills do, a drill press used as a lathe to turn down the bushing to size, a hammer to tap the bushing in place. It's easier than you're making it out to be.

 

[halo]

Thanks for all the info on this. Not sure which way to go but the welding idea sounds like it might actually work.

I was really under the impression that you could just get a bit slightly larger than the hole and drill out the amount needed to firmly press the bushing in place. From what, I'm reading, it sounds like that wouldnt work.....