After removing the bolts, it really shouldnt be more than 2-3 inches to get it off the end of the output shaft.

Is this a 5 speed trans?
The 5-speed has a detent ball that is installed with the viscous coupler and snapring on the center differential outer pinion gear for it to retain the output shaft.

If you have OVERLY excessive play and this detent ball is properly installed, your centerdiff cover or gearset are badly destroyed...

or a severly worn output shaft detent from a poor installation.

If its as simple as your ouput shaft getting stuck in your transfer case,

get a blunt object to fit between the transfer case and trans, rest it on the output shaft and give it a tap (A tap not a bludgeoning) to free it. Then put a small amount of grease on it when installing it back on.

The trans is a 5 speed. There doesnt seem to be enough room to move the transfer case over to the driverside far enough to get the shaft to pull out of the trans. It is stuck in the transfer case and easily comes out of the trans. Whole reason I am doing this is to get that trans out and see whats broken in there.

I have tried taping on the shaft, have tried to "slide" the xfer case off with a flathead and hammer, seemed like it moved about an eighth inch.

Am I going to have to drop the driveshaft too now?

Sounds to me like your center diff took a shit.
The output shaft isnt going to have enough room to come all the way out with the transfer case. So you need to find a way to get the shaft out of the transfer case. It could be possible that the output shaft's splines could be seized into the transfer case somehow after attempting to drive it after the damage was done. But don't quote me.

I havent quite seen this happen before, but I'm sure someone has.

It would be worth it to email Tim Zimmer with the issue, or PM him on here (twicks)

97gsxIA said:

Sounds to me like your center diff took a shit.
The output shaft isnt going to have enough room to come all the way out with the transfer case. So you need to find a way to get the shaft out of the transfer case. It could be possible that the output shaft's splines could be seized into the transfer case somehow after attempting to drive it after the damage was done. But don't quote me.

I havent quite seen this happen before, but I'm sure someone has.

It would be worth it to email Tim Zimmer with the issue, or PM him on here (twicks)

Click to expand...

Yeah, Im sure the diff is trashed. I will be surprised if the trans is salvageable.

I just read on another forum to lock some vice grips on the shaft and trying to tap it outta the transfer case. Ill try that tomorrow.

The more secure the transfer case is while tapping the shaft out, the more force is exerted on the shaft instead of the xfer case, making the it easier to get the shaft out. Keep that in mind as you try to get it out.

97gsxIA said:

The more secure the transfer case is while tapping the shaft out, the more force is exerted on the shaft instead of the xfer case, making the it easier to get the shaft out. Keep that in mind as you try to get it out.

Click to expand...

Its gonna be supported by a jack so that should help.

Ive had this happen to me once, long ago. In my case, the fluid had leaked out of the Tcase enough so that the pinion and side gear within actually sheared the teeth right off, and it got so hot that it literally welded the shaft to the tcase splines. I ended up getting the transmission completely ready to come out- axles out, bell housing bolts out, cables off, subframe braces off, then I was able to pull the transmission away from the block just enough that I could pull the shaft and tcase off together. You will need a new tcase and shaft, and be sure to retrieve the little retainer ball that holds the output shaft in the center dif.

Cut the shaft

danl said:

Cut the shaft

Click to expand...

I really hope I dont have to do that.

Ok UPDATE

Pulled the side of the trans apart and found the ball bearing. Put it back, even put a C clamp on it and it will NOT hold the output shaft. As soon as I put any force on the Xfer case the shaft slides out with it.

What do I try next?

I told you what to try a few posts up.

clamp a good set of vice grips on the shaft and nail them with a mini sledge a few times. This may break it loose.

OP just needs to pull the transmission as far away from the motor as possible, then angle the far side of the transmission up and pull the shaft and t case out of the transmission together. It will come out and its the easiest way to make it happen in this case. Those splines are either twisted together and seized, or they've basically welded together. Ive been through this before myself, and you can either get it out quickly and easily, or you can fight it all day and still not get it out.

kchaazz said:

OP just needs to pull the transmission as far away from the motor as possible, then angle the far side of the transmission up and pull the shaft and t case out of the transmission together. It will come out and its the easiest way to make it happen in this case. Those splines are either twisted together and seized, or they've basically welded together. Ive been through this before myself, and you can either get it out quickly and easily, or you can fight it all day and still not get it out.

Click to expand...

This is what I'm going to do. Thanks. I work out of town 5 days a week and don't get much time to wrench or check back here.

Well did like mentioned above and pulled the trans and transfer case together. Even the drive shaft was still in. That fell out once I started to drop the trans and eventually I was able to pull the output shaft with the transfer case then finally drop the trans. Shaft is frozen in the transfer case.