timing chain woes

Alright, I have a '99 TJ with a 4.0 stroked.
4,000 miles after motor rework, snapped the chain wiping out both gears.
Now, almost 10,000 miles later, took out a few teeth. (just started to tear into it, no visual yet)
The chain is still intact, though.

Ok, now for the help....
I do have endplay in the cam, haven't measured yet, but not tight.
How much resistance is normal when I try to spin the cam by hand (w/sprocket) with all the valvetrain in?

I'm really leaning tward pulling the cam to inspect.  Do I need to pull the front clip or can I weasel it through the grill?

Can you replace cam bearings with the motor in?

I always like timing gear drives... Anyone make then for the 4.0's?  
99tj/ 4.6 stroker / 4.88 / '06 rubicon axles / 7"rockkrawler l/a / steering upgrade / agr pump psc box and hydro assist / mm 10.5k hyd. winch / 35" Trxus MT / comp cams xtreme 4X4 cam

Got an update.  Had some time to look at it.  Took out about half the teeth on the crank gear.

Removed the chain and put the cam gear back on.  Tried to see if there is any endplay, but none!!! Pulled the bolt w/ washer and slinger off to find the nose of the cam looks to about .025" recessed from the gear.  Is this normal?  
I noticed the washer on the cam gear bolt is cupped in like a spring washer.

Any insight on this would be greatly appreciated!!!!  
99tj/ 4.6 stroker / 4.88 / '06 rubicon axles / 7"rockkrawler l/a / steering upgrade / agr pump psc box and hydro assist / mm 10.5k hyd. winch / 35" Trxus MT / comp cams xtreme 4X4 cam

If the camshaft appears to have been rubbing against the thrust washer, examine the oil pressure relief holes in the rear cam journal. The oil pressure relief holes must be free of debris.

Is it a stock cam profile? If it's high lift, are you using the recommended valve springs from the cam manufacturer? And if they're heavy load springs, is the timing set you're using ok for the high load springs?  

Stock cam. Don't have it out yet. The front thrust washer has markings on it, but no wear or scoring.  Everything is clean so far.... except for those stray gear teeth!!  Without the gear, I can push the cam back just over 1/16" and pull it right up to the thrust washer w/out too much effort thinking that there are no substantial ridges in my cam bearings.

It just seems like there should be some gap on both sides of the thrust washer.  The nose of the cam on the back side and the gear on the front.  Its like the shoulder on the sprocket needs to be thicker, like its supposed to bottom out on the cam but have a few more thou. than the washer.

Maybe I'll mic the washer and then bolt up the gear without it.  Then I'll measure the gap between the cam and gear w/ feeler gagues.  I would guess... if I'm not out in left field on this one, that the washer needs to be 8-15 thousandths under.  
99tj/ 4.6 stroker / 4.88 / '06 rubicon axles / 7"rockkrawler l/a / steering upgrade / agr pump psc box and hydro assist / mm 10.5k hyd. winch / 35" Trxus MT / comp cams xtreme 4X4 cam

Do you have a thrust plate?

 

Yes I do, and it doesn't seem to have much wear at all, but the plate seems to be pinched once I draw up the cam gear.  If it doesn't rain, I'll look at it more tonight.  
99tj/ 4.6 stroker / 4.88 / '06 rubicon axles / 7"rockkrawler l/a / steering upgrade / agr pump psc box and hydro assist / mm 10.5k hyd. winch / 35" Trxus MT / comp cams xtreme 4X4 cam

Probably going to pull the cam today or tomorrow, can you get it out through the grill?  I guess if its in the way, I can undo my motor mounts, support the motor and walk it left or right to line up.  
99tj/ 4.6 stroker / 4.88 / '06 rubicon axles / 7"rockkrawler l/a / steering upgrade / agr pump psc box and hydro assist / mm 10.5k hyd. winch / 35" Trxus MT / comp cams xtreme 4X4 cam

The grill and the radiator can come out together without much effort. Just leave the fenders hanging there.

The thing that sucks is the condensor if you have a/c. Maybe you can wire the condensor up and out of the way so you don't have to evacuate and recharge.

It's usually best to get the grill out of the way so you have room to work. The cam needs to go in and out straight and it's sometimes difficult, even with lots of room, to keep from knocking the lobes on the bearings.  

Sweet, never really looked into it.  No A/C helps too!  Going to go with a comp cam sk68-232-4 cam kit.  
99tj/ 4.6 stroker / 4.88 / '06 rubicon axles / 7"rockkrawler l/a / steering upgrade / agr pump psc box and hydro assist / mm 10.5k hyd. winch / 35" Trxus MT / comp cams xtreme 4X4 cam

Alright, got the new cam in and running!!  It's no night and day difference, but the throttle response is snappier and the bottom end has a little more grunt.  Now all I need is a cold air intake and bore out my throttle body!!!  
99tj/ 4.6 stroker / 4.88 / '06 rubicon axles / 7"rockkrawler l/a / steering upgrade / agr pump psc box and hydro assist / mm 10.5k hyd. winch / 35" Trxus MT / comp cams xtreme 4X4 cam