Has anyone tried a jam nut approach?

 

Follow-up, just wanted to let everyone know I repaired the 5th gear problem with help from Ryan. I drove to his place early in the morning and by 10:30am we had everything apart. The only problem was the 5th gear nut was stripped so we spent hours looking for one. We applied a few good welds to keep the nut on and now I have 5th gear again. I can't thank Ryan enough for his generosity.

 

That's cool members helping members! That's what's it all about!

 

Standard Transmissions makes a full splined 5th gear main shaft ans nut that fixes the problem for good.

 

Im sure they do, but our fix was only 40 bucks, and I'd bet my truck on it that it never ever backs off again! between the locktite and the spot welds,and the lock nut, its not moving!!!!

 

Well I pulled the transfer and transmission replaced fifth gear and put it back together again by myself in 5 1/2 hours. Which beat my previous record! Just a few things about pulling the cross member, don't use a big pry bar and a couple of 2x4's those 2x4's turn into projectiles when the cross member becomes dislodged and no matter how fast you think you are you can't get your big head completely out of the way in time. One other thing when replacing the aforementioned cross member apply a generous coating of axle grease on the frame and cross member THEN beat the heck out of it with a big hammer it makes it so much easier that way. Another thing, when working by yourself be VERY sure the lift you are using to hold your transfercase is securely fastened to the transfercase or you could find yourself with a transfercase on your chest without enough room to dislodge the heavy little bugger! These are just a few thing I found while doing what is turning into routine maintenance on my truck.

Goodnight and Goodluck!

 

If all else fails you can always get this,the perfect permenant fix.
Mainshaft kit