1G Output shaft and transfer case question...

[5150DSM]

I just finally got my Transfer Case off today after having to use vice grips to wiggle the output shaft out of the TC. It (the shaft) kept pulling out of the tranny whenever I tried to pry the TC off.

I have read a couple of threads regarding this same issue but there were conflicting opinions as to the seriousness. Can someone please offer a definitive opinion/answer?

The question is, is the center diff bad or going bad as a result of the shaft pulling out of the tranny?
Are the thrust washers most likely worn or is there something else I should be aware of?

I never had this issue on my manual cars but my new car is an auto and it's the first AWD auto I've had. I read that it is common on auto cars but not necessarily a failure. Though I'm not sure how true that is.

Thanks for taking the time to read and answer this thread, I'm rebuilding my car right now and need good information to do it properly.

 

[->PrOjEcTGS<-]

There is a retaining ball that holds that shaft in place. The ball is sandwiched between the Viscous coupler, center diff, and the output shaft. Somehow this retaining ball is no longer in there. I had this same problem with a trans I recently tore down. Luckily in my case the trans had been opened up before and they just forgot to put this ball back in.

If it has fallen out for whatever reason then It's floating around inside the trans. It had to have gone through the center diff before it ends up in the trans though.

Now, is it a serious failure? Not really... Your output shaft will stay in place as long as your T-case is bolted up to the trans. So, as long as the ball isn't floating around in the trans, possibly creating damage, then I wouldn't worry about it too much.

It's not hard to fix though. Pull off the trans end cover, pop off the VC C-clip, and pop up the VC. Replace the output shaft and output shaft retaining ball and put the VC and C-clip back on. RTV up the trans cover and you're done.


AHHHHH SHIT.... Just read it's an Auto... I think the same principles still apply to them though.

 

[rock1t]

AHHHHH SHIT.... Just read it's an Auto... I think the same principles still apply to them though.

 

[5150DSM]

Thanks. I know about the retainer bearing. The shaft itself is in good shape, just somewhat rusty. There is no damage that I can see. Also, the shaft seems to lock back into the tranny as long as I don't yank too hard. I'm wondering if there is any difference between the auto and manual trans?