Transfer case install-spline problem

black92_tsi_awd · Dec 5, 2004

I guess since I'm a newbie so this belongs here. Just bought a basically stock 92 Talon last month...lost the trasfer case bearing and seal on the transmission side. The bearing race shredded and seized to the shaft. I got a got a used shaft and got the transfer case back together. Problem is it looks like the blown bearing caused the transmission output shaft splines to deform from the wobbling See the picture. Now the new transfer case shaft only slides halfway onto the transmission splines. I'm thinking of using the mounting bolts to pull the transfer case on. Anybody ever done this? I'm worried I'll get it on and never get it off?

steve · Dec 5, 2004

I assume you checked to make sure that the spline count is the same on the "new" part and that it's splines aren't worn. I'd replace the output shaft on the trans. Cranking the transfer case down on that is just going to damage the splines on both sides.

Steve

black92_tsi_awd · Dec 5, 2004

Spline count is the same. The transfer case slides on fine until about halfway, where the trans splines stop twisting in the picture. I would imagine that replaceing the output shaft involves pulling the trans? Not real thrilled about doing that in the middle of winter in the driveway!
The old shaft still goes on, turns slightly as the thread splines bottom out. I could probably use it if I could get the old inner bearing race off the shaft. It's seized pretty good and a press couldn't get it off. Might have to try torching it to heat it and then pressing it....

86MCSS · Dec 5, 2004

[not tryin to hijack] Whats involved with changing the output shaft? I tried Vfaq and got nothing.

David15151 · Dec 6, 2004

did you try just taking it to the dealer and getting a free one from the recall?

kalla · Dec 6, 2004

It is not uncommon for an output shaft to twist like that from abuse or a mechanical problem like you mentioned. Unfortunately you will have to open the transaxle to remove the old output shaft and put another one in.

I have not replaced an output shaft in a DSM transmission, but I bet it can be done with the trans still in the car; it can be done on the 3000GT VR-4 and Stealth, as I've done several of those with the trans in the car. In those cases the output shaft was twisted completely in two, like so:

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Good luck

black92_tsi_awd · Dec 6, 2004

David15151 said:
did you try just taking it to the dealer and getting a free one from the recall?

I thought about it, but it's already torn apart and I'd have to tow it. Plus I've never had good luck with any dealer servicing my car, just don't trust them!

black92_tsi_awd · Dec 6, 2004

kalla said:
It is not uncommon for an output shaft to twist like that from abuse or a mechanical problem like you mentioned. Unfortunately you will have to open the transaxle to remove the old output shaft and put another one in.

I have not replaced an output shaft in a DSM transmission, but I bet it can be done with the trans still in the car; it can be done on the 3000GT VR-4 and Stealth, as I've done several of those with the trans in the car. In those cases the output shaft was twisted completely in two, like so:

My buddy who races Eclipses is pretty sure we could remove the trans shaft without dropping the trans. I'm going to try to remove the bearing race tonight from the old one, if I can't I'll have to pull the trans shaft. I'll report back later.

kalla · Dec 6, 2004

I dunno man, that shaft looks like it's already deformed, meaning it's weakened and could break with sufficient input torque .. proceed at your own risk but I would replace it.

black92_tsi_awd · Dec 7, 2004

Well it looks like I'll be replacing the trans shaft. Tried getting the bearing race off the old transfer shaft (that fits the deformed trans shaft), it's toast! The bearing definitly spun a while before it seized... :cry:

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Transfer case install-spline problem

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