Transmission Output shaft came out with Transfercase During Removal

[CPHunter]

So i had a Oil leak on my oil pan that i wanted to fix. So while removing the transfer case to get to some Oil Pan bolts.. and after fighting with the car i noticed that i was having a hard time because the output shaft had moved out of its secure place inside the trans . Long story short, i finally took the T-case off... I'm sitting at my desk with the input shaft in my hand...... Anyway... How much of a pain in the rear is this gonna be for me to fix... I'm going to do the work myself...

Purple Bar in picture is one i speak of... Also this isn't my trans.. Just one i found on google

You must be logged in to view this image or video.

 

[My1GLaser]

Its not too hard to do. You have to take the end case off the trans, remove the VC and slide the output shaft back in and put the ball bearing in the ctr diff shaft hole then slide the VC back on and put the circlip in place. Use Ultra Grey RTV to reassemble.

While you're in there make sure the end nuts are torqued properly. Shifter wiggle/movement while in gear?

Also where did the ball bearing go that was in there? Make sure there isn't any damage too.

 

[evileagleawd]

Check the spline wear while your there. The output shaft are known to wear right where they slide into the t-case. Should have a nice box not a /\ edge on the shaft or the t case!

 

[turboglenn]

You should be able to shine a light in the hole and see a small ball bearing laying in the hole/splines if there was one there, chances are the previous owner maybe lost it and just stuck the shaft in, which althogh can't harm much isn't properly installed as the VC has to be removed to let the ball out and the shaft be removed (again as said above easy work)

the oil from input shaft has to have the entire trans taken apart because it's behind the bell housing and the gear clusters and shift rails all need pulled.

best of luck man, it's not hard if you've got a lot of mechanics style tools in your stock, but if you've never been a mechanic in your life it might be best to get help from some one confident in doing it, once you get to it though it's so easy to replace you'll alsmot be mad at what you went through to access it , the t-case shaft i just pry out with a seal puller or you can screw a dryway screw into it by about 1/4 inch and pull it with pliers (ghetto method)

gimmea minute and i'll get you natinal seal brand part numbers for all of it so you can buy them at advanced or autop zone, most others won't have them in stock

the numbers at front of sentences are national part numbers (that's a brand) the ones after are alternates that may work too

MY parts numbers for seals from 1st hand buying

710199 Is left front CV shaft seal (bh3340e)

223543 = right front CV to trans seal (759042?)

712007 input seal behind bell housing for main

shaft

11592 (believe this is t-case "in" and trans

"output shaft") same seal for trans and t-case

(same seal for shaft from trans and around splines

into t-case)

Not sure how far you are fromomaha but if you cover my gas and have some ice water i'llcome helpo you ifit's not too many hours away, i'll even bring tools and some extra trans parts and teach ya what you're doing

well, mapped it

damn you'realmost 9 hours away, i was hopin i could help some one out just for gas and some ice water to get there and back , try and be nice and it's the furthest fromme you can get in MO

 

[CPHunter]

Thanks Guys... and thanks Glenn for Offering... But I'm really in L.A.... I really need to change that

 

[4pistons]

shine a light in the hole and see a small ball bearing laying in the hole/splines...... chances are the previous owner maybe lost it and just stuck the shaft in, which althogh can't harm much isn't properly installed

It CAN harm a lot! Without that ball in there the output shaft is allowed to slide back and forth under acceleration and THAT'S what wears out the splines!
Be SURE to put that retaining ball back in there!

Rick - '92 GSX

 

[98gstbrad]

Hey I was wondering if you have fixed the transmission output shaft yet because I have the same problem on mine and I was wondering how hard it was for you seeing as this was your first time doing this. Let me know please.

 

[talon2gbuyer]

anyone have the part number for the retaining ball? or is any old ball bearing good for this?

 

[19Eclipse90]

MF540008, listed as a steel 1/4" ball.

 

[talon2gbuyer]

you are awesome. thank you!

 

[talon2gbuyer]

hey all, one last thing. I have a buddy who is working on a 96 awd tsi, and it seems that the trans shop that did his clutch lost the ball bearing for his output shaft. Now the service manual i'm looking at shows two bearings for the output shaft, a front and a rear sealed ball type bearing. Now ive read that there are instances where a single steel ball bearing acts as a bump stop for the output shaft from falling out of the trans, is this true? or did I read something incorrectly?

His problem is that his output shaft can be pulled completely out of the trans with nothing stopping it. So my guess was he was missing the 1/4'' ball bearing that acts as a bump stop. It isnt so much that I cannot find a bearing for him, but that his output shaft doesn't seem to have a seat for that said ball bearing. Can anyone help me out with a picture and some advise?

Thanks!

 

[19Eclipse90]

Plenty of info and pictures here: 99 GSX Manual Transmission Rebuild

 

[synthetek]

It isnt so much that I cannot find a bearing for him, but that his output shaft doesn't seem to have a seat for that said ball bearing. Can anyone help me out with a picture and some advise?

Thanks!

The ball rides in this groove and it keeps the shaft from coming out.

You must be logged in to view this image or video.

 

[4pistons]

Read my post above.

Rick - '91 GSX

 

[talon2gbuyer]

Syn, that pic helped tremendously! thank you all for the help once again