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Transfer case tolerances


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I'm in the middle of a 4l80e swap and as the Tcase has to come apart anyway it seams logical to give it a full refresh at the same time. 

Just looking to see if there's anyone that can advise on tolerances for the Tcase as I'm struggling to find anything online other than a basic assembly guide of "put this thing there" 

On my rear output the bearing to case clearance can only be described as a hotdog down a hallway with lots of play. I did notice this issue before removal as the slip yoke to the prop had a lot of radial play. Fairly sure I will need a new case half to fix that one. Its bad enough that the annulus carrier has made contact with the planet gear carrier and has raised burs on the face. 

The thing I'm not sure on is the input shaft bearing clearance to the case. It can just drop straight in with no resistance. 

I've rebuilt my fair share of gearboxes and diffs and don't recall ever having a bearing into a case that wasent press fit. Should this be a press fit bearing or is it fine and I'm overthinking things being used to cars that are a bit less agricultural than this. 

If anyone has a spec sheet of tolerances they can share that would be great, or is it literally as easy as slap it together and send it. 

Also any tips for upgrading or addressing weak spots on this Tcase? 

Plan is to run around 650-700hp but it does double duty as a work truck that tows so don't want to grenade it. 

 

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