I just bought a duramax and he told me the tranny/transfer case gasket was leaking so I crawled under there and that's what it looked like to me so I removed the transfer case and the part that the transfer case bolts on fell off. I thought that I could remove the rear housing to weld it. Now it is all welded but I cant get the housing all the way on. The planetary gears come out with the housing. I'm sure I am installing them correct but I'm about an 1/8 inch away. Can any one help??? Can you install the gears from the back or do I have to remove the transmission to get the housing back on??

STOP! You have done one or two things that spell big trouble... but don't panic, it can be corrected.

The planetaries likely slid rearward when you removed the cover. The only good way to remove it is to undo the output shaft retaining nut and hold in on the shaft as you remove the cover.

So what to look for?

1. A clutch friction plate may have dropped off the back of the ringgear and is now holding it too far rearwards. This is most likely the C5 at the very rear, but could also be the C4 on the middle planetary.

2. A thrust bearing dropped down out of place.

3. Lost spline engagement on the main shaft spacer between the rear two sun gears.

You're likely going to have to remove the C5 clutch pack and P3 Carrier (rear most carrier) to inspect.

If I were you I'd go get a new output housing 29542109 and snapring 29541534, as I doubt the weld will hold without recracking in the heat affected zone. The later rear cover has stronger ribs and other strength inprovements.

Crafty1---- Damn if I don't believe you know what you're doing !!!!!!!

I think Crafty1 has done this a time or two! Do as he says and save yourself more trouble.

Ya think ;)

What I admire is jzts0214 willingness to dig in and work on it and recognizing the problem and knowing when to stop for help! Saves a big tranny repair bill. I've seen those too that were blasted back together with an impact gun never recognizing that 1/8'' of a problem. Ouch!

Patience and attn to detail will get you back on the road...

I just go done putting the thing back together and everything is good. I did it with the tranny still in the truck and replaced the rear cover. I also had the driveshaft leghtend due to this truck has a 14 inch lift and I bought the suncoast brace. Drives great now.

Good job! That's great to hear. Its good that you caught the bind-up on the initial reassembly. If you had crammed it back together it would have certainly broken parts and tornup a lot inside. Thanks for the update.

Crafty1----You're the Man !!!!!!!!