techboy
5+ Year Contributor
- 541
- 436
- Feb 3, 2018
-
Lehigh Valley,
Pennsylvania
A ran into a problem during my AWD swap with my transfer case having a different spline count than my transmission. After posting a question I learned that you can swap output shafts on the transmissions fairly easily. I documented the process below as I did with pictures. Hopefully it'll help someone out down the road.
First thing you need to do is remove the outer 5th gear cover on the transmission. You can actually do this with the trans in the car. Note however, I had no axle, suspension, or control arms in the way, so it might be more difficult if you don't as much taken apart already apart as I did.
The cover is held on by 9 or 10 14mm bolts. Two on the bottom are very long, the rest are all the same.
Once the cover is off, you'll see this. The 5th gear syncro will probably fall off when you remove the cover. Don't lose it.
This is viscous coupler, this is what we need to remove to get the output shaft out.
There's a snap ring that holds it in place. You'll need to get your snap ring pliers to get that thing off. It's not the easiest clip to get off.
Once you get the clip off, the coupler should slide right off in your hands, if not, get to two screw drivers and pry gently forward and it should slide off.
The output shaft is held in place by a retention ball.
There's a spot in the shaft at 180 degrees for a 2nd one on the other side, but there's only one, don't worry you didn't lose one, just don't lose the one you have.
I used a magnet to lift the one out.
Once you remove the retention ball, the output shaft will slide right out the opposite side.
Here it is completely removed.
Here's both shafts side by side.
Up close, you can pretty clearly see the difference between the 22 and 23 spline output shafts.
To reverse the process, slide the shaft you want in place. Put the retention ball back in place and slide the viscous coupler back on. Put the snap ring back in place.
Now you need to put the 5th gear syncro back on. To hold it in place so it didn't fall off while putting the cover back on, I packed it with vaseline.
Time to put the cover back on. clean the flange real well from all debris. I even used a little brake cleaner to clean out the inside.
To put the cover back on, use a silicone based RTV. I had some RTV Blue on hand, so that's what I used, you might prefer something different. I can't stress enough, you don't want to GLOB this stuff all over or you'll have squeeze out inside the transmission which you really do not want. Use a very very very thin even coat. It's hard to tell from the picture, but this is a paper thin coat of RTV.
According to the FSM, the outer cover calls for 29ft pounds. The cover is aluminum, if you over torque it you'll crack it. If you don't have torque wrench, go buy one. Don't be stupid.
All back together.
Good luck.
First thing you need to do is remove the outer 5th gear cover on the transmission. You can actually do this with the trans in the car. Note however, I had no axle, suspension, or control arms in the way, so it might be more difficult if you don't as much taken apart already apart as I did.
You must be logged in to view this image or video.
44The cover is held on by 9 or 10 14mm bolts. Two on the bottom are very long, the rest are all the same.
You must be logged in to view this image or video.
Once the cover is off, you'll see this. The 5th gear syncro will probably fall off when you remove the cover. Don't lose it.
You must be logged in to view this image or video.
You must be logged in to view this image or video.
This is viscous coupler, this is what we need to remove to get the output shaft out.
You must be logged in to view this image or video.
There's a snap ring that holds it in place. You'll need to get your snap ring pliers to get that thing off. It's not the easiest clip to get off.
You must be logged in to view this image or video.
Once you get the clip off, the coupler should slide right off in your hands, if not, get to two screw drivers and pry gently forward and it should slide off.
You must be logged in to view this image or video.
The output shaft is held in place by a retention ball.
You must be logged in to view this image or video.
There's a spot in the shaft at 180 degrees for a 2nd one on the other side, but there's only one, don't worry you didn't lose one, just don't lose the one you have.
I used a magnet to lift the one out.
You must be logged in to view this image or video.
Once you remove the retention ball, the output shaft will slide right out the opposite side.
You must be logged in to view this image or video.
Here it is completely removed.
You must be logged in to view this image or video.
Here's both shafts side by side.
You must be logged in to view this image or video.
Up close, you can pretty clearly see the difference between the 22 and 23 spline output shafts.
You must be logged in to view this image or video.
To reverse the process, slide the shaft you want in place. Put the retention ball back in place and slide the viscous coupler back on. Put the snap ring back in place.
You must be logged in to view this image or video.
Now you need to put the 5th gear syncro back on. To hold it in place so it didn't fall off while putting the cover back on, I packed it with vaseline.
You must be logged in to view this image or video.
You must be logged in to view this image or video.
Time to put the cover back on. clean the flange real well from all debris. I even used a little brake cleaner to clean out the inside.
You must be logged in to view this image or video.
To put the cover back on, use a silicone based RTV. I had some RTV Blue on hand, so that's what I used, you might prefer something different. I can't stress enough, you don't want to GLOB this stuff all over or you'll have squeeze out inside the transmission which you really do not want. Use a very very very thin even coat. It's hard to tell from the picture, but this is a paper thin coat of RTV.
You must be logged in to view this image or video.
According to the FSM, the outer cover calls for 29ft pounds. The cover is aluminum, if you over torque it you'll crack it. If you don't have torque wrench, go buy one. Don't be stupid.
You must be logged in to view this image or video.
All back together.
You must be logged in to view this image or video.
Good luck.
