I'm rebuilding a QT from a few spares and am looking for guidance on what's acceptable when reusing bearings. I have two cases to choose from, one with the square-ring gasket in the top cover and one without. (I was surprised to find out some came without the gasket.) The case without the gasket has lower miles but has some chunks missing from the aluminum in the outer support webs around the rear output shaft. I'm favoring the case with higher miles because it has the gasket and the only damage is a helicoil insert in the top cover where the low range bolts up.
All the needle bearings feel OK to me. The lower-milage case has bearings that feel just a bit tighter but I don't think I can pull those without screwing them up.
I think I screwed up the roller bearing on the rear output shaft trying to pound it out ("rear annular bearing"). I was pounding on the P/T kit coupler instead of the output shaft and now it feels notchy sometimes, spins free sometimes. Gonna tear the other case apart to check out that bearing.
BJ's has all 4 types in stock, six total. A full set would cost about $240 plus I'd probably pay a machine shop to pull and press them in as insurance against screwing anything up. But that's a lotta coin for piece of mind.
These cases seem overbuilt and the bearings seem in great shape overall. What have y'all found when reusing bearing? What's your yardstick when choosing between replacing or reusing the bearings?
'78 Waggy: 401/QT pulling the rust down the road. 6.2L +turbo waiting in the wings.