Rear Output Housing Shims

For those interested, the rear output bearing race (cup) had indeed come out of the TC a bit during disassembly, which was what confused me in the first place.  The recommended videos and help from you all helped me literally piece things back together.  

I thought I was going to replace only the rear TC seal, but ended up doing both front and rear, and front differential, adjusted the brakes, put in a new exhaust system (thanks, Kaiser Willys), lubed the entire chassis, fixed speedo drive, and installed new transfer case and 2WD/4WD shift levers and pin.

Again, thank you all for your patience, wisdom and camaraderie.  

Berdo

This meant I had nearly triple the number of potential leak points because you couldn't use a couple thick shims to get you closer to the correct tolerance. 

John at Midwest Military gave me a set of originals, sill in the greasy envelope. They were a perfect set of varied thicknesses. I was able to minimize the number of shims. I also switched from Permatex red spray gasket maker to the copper. Tight as a drum now.

Combined with a sealed front bearing on the T90, and the Novak t-case pan, it does not leak at all.

Of course, I just jinxed myself.

Metalshaper is awesome. Brian is very passionate about these old Jeeps. Another source is Ron Stiver. He wrote. Rebuild manual many years ago, and created some very detailed step-by-step guides for the T90 and Dana 18.