Intermediate shaft stuck in t-case?

[ESIRstarion]

Having an issue with the transfer case removal on my '90 GSX. I removed the 5 bolts and pryed the t-case away from the trans, but the output shaft does not want to come out of it....I spent about 2 hours last night trying to remove it; moving it from side to side, up and down and it still will not come off the shaft.

Any tips or suggestions are appreciated.

 

[interex]

The shaft will actually pull out of both units. Just push the transfercase back against the transmission and with a quick hard tug and it will seperate from either the tranny or the tcase.

 

[SnowBird]

Yeah, it has to come out. I know you are saying it wont come out, but just keep pulling, wiggling it like a seesaw. If you are gonna try to pry, pry a couple different spots evenly so you just dont pinch it even worse.

 

[Auto RS T]

The shaft will actually pull out of both units. Just push the transfercase back against the transmission and with a quick hard tug and it will seperate from either the tranny or the tcase.

The shaft should remain in the transmission. If yours has come out of the tranny, you have a problem. The output shaft is held in the trans by a steel ball and the Viscous Coupler.

ESIRstarion: Your teeth may be damaged on the shaft. Sometimes they spiral around the output shaft making it very hard to take off. You just have to keep prying. There is a tech article on replacing the shaft in the car, if this turns out to be the case.

 

[brian9397gsx]

i work at a chrysler dealership ive heard of horror stories from the tranfercase recall days of the shaft actually doing what you said and having to replace the shaft and t case hope that will not be your prob good luck

 

[->PrOjEcTGS<-]

The shaft should remain in the transmission. If yours has come out of the tranny, you have a problem. The intermediate shaft is held in the trans by a steel ball and the Viscous Coupler.

ESIRstarion: Your teeth may be damaged on the shaft. Sometimes they spiral around the intermediate shaft making it very hard to take off. You just have to keep prying. There is a tech article on replacing the shaft in the car, if this turns out to be the case.

Yep this could be the case. I've seen it happen a few times on here.

BTW, it's not the intermediate shaft. It's the Output shaft. The intermediate shaft is inside the trans and has 1st and 2nd gear's hub/sliders on it.

 

[ESIRstarion]

Yep this could be the case. I've seen it happen a few times on here.

BTW, it's not the intermediate shaft. It's the Output shaft. The intermediate shaft is inside the trans and has 1st and 2nd gear's hub/sliders on it.

Thanks! I'm almost positive that the splines are damaged since there was almost no fluid in the t-case when I drained it.

I reviewed the tech article.......If the splines are spiraled is it even possible to take the t-case off the shaft? I'm coming to the realization that the trans and t-case will have to be dropped and replaced.

 

[talondave]

I have had this happen and the t case got hot and kinda welded to the shaft.I had to cut the shaft to get it apart and it was not fun.But you might get lucky and it come apart. Good luck