Swaping the output shaft of my AWD Tranny!!

[Cheks_Talon_TSi]

I bought a Tranny for my 90 AWD. unfortunately the transmission i bought was a 23 spline and mine is a 22 spline. As far as I have read on this forum, I got 2 options:

1.- Swap the output shaft (put my old 22 spline into the recently bought trans, in order to make it fit on my T-case).
2.- buy a 23 spline T-case.

which of this two options is better??? which one is cheaper???

If i decide to go to with the option #1 , how difficult will it be?? will i need to change anything more in order to make this swap???

Please let me know, any help or suggestions will be very appreciated...

sergio g

 

[dsmmatt28]

Option 1 is the cheapest and its not very hard. Take off the bolts that hold the outer case on tranny. Once that is off you will see the viscous there will be clip holding that on use a pair of c clip pliers to remove that. Once that is off you will have to pry the viscous off it will be difficult but not that difficult just a little force is all that is needed. When the viscous is off there will be a little hole with a little ball in it. Remove the ball and then the shaft will slide out. Slide the new shaft in. Replace the ball. It has to sit in the grove off the shaft. When you take the shaft out you will see the grove and know what im talking about. When putting the viscous back on it only goes on one way only look at the groves and match them up. You will have to use a hammer to pop it back on. Replace the c clip and use silicon when puting the case back on. This shouldnt take no more than a hour for a first timer. It takes me 20min

 

[dsmmatt28]

Was thinking about your car and you will have to use your 90 shifter bracket aswell the one that is on the the tranny were the shifter linkage is and bolts to. Aslo the actual shifter lever thats on the the tranny is not the same its a tad bit longer look at it close. You will see what im talking about. When you put the shifter likage on the you will notice that it a little off and not sitting straight you will have to drill a small hole next to where it would have sit so the shifter linkage is straight use a small bolt and nut. If you dont your car will not get into gear. I have been through at least 7 trannys in my dsm life time. I have a 93 tranny in there now and my car is a 90. My 93 is built and shifts like a warm knife through butter at 7k rpm 10000 miles on it so far.

 

[Cheks_Talon_TSi]

Was thinking about your car and you will have to use your 90 shifter bracket aswell the one that is on the the tranny were the shifter linkage is and bolts to. Aslo the actual shifter lever thats on the the tranny is not the same its a tad bit longer look at it close. You will see what im talking about. When you put the shifter likage on the you will notice that it a little off and not sitting straight you will have to drill a small hole next to where it would have sit so the shifter linkage is straight use a small bolt and nut. If you dont your car will not get into gear. I have been through at least 7 trannys in my dsm life time. I have a 93 tranny in there now and my car is a 90. My 93 is built and shifts like a warm knife through butter at 7k rpm 10000 miles on it so far.

Thanks for you advices dsmmatt... Seems I will have to do some work in order to do a good transmission swap on my 90 AWD... Thanks, I will follow all of your instructions...

Any other suggestions or mods I will need to do???

thanks in advance

sergio g

 

[dsmmatt28]

just pm me if you have any problems or questions

 

[9520g]

Im having a similiar problem, which exactly is the outer cover on the trans case?

 

[RoasT BeeF]

You actually have to remove 2 cases and the center diff to get the output shaft out. You can follow this procedure http://www.geocities.com/spencerhut/talon/center_differential_repair.htm for removing the output shaft. You will see how it comes out once you are in there.