techboy
5+ Year Contributor
- 534
- 420
- Feb 3, 2018
-
Lehigh Valley,
Pennsylvania
So I ran into a major snag with my AWD swap last night. I spent an hour or so trying to install the transfer case and it just wouldn't slide on. I gave up and went to bed. I got to thinking today that maybe there was an issue with the splines. I had checked and double checked the output gear ratio, but never the input shaft splines. So, it turns out my transfer case is a 22 spline while the replacement trans I picked up is a 23 spline. Here's where I get a little confused and could use some insight. I had to replace the original trans that came with my donor car for the AWD swap b/c it was damaged. The number on that trans was KW5M332NPZT. I made sure when I purchased my replacement it bore the same number so I wouldn't run into T-case issues. I still have the old trans, and when I go back and count the splines on the input shaft it counts 22 as well (same as T-case).
As far as T-cases go, it has been my understanding through research that 89-90 T-cases had a 22 spline count and where in an all aluminum housing. The 91-99 all had a 23 spline with the 97-99's having the different gear ratio on the output. Unless I am crazy, my T-case is not all aluminum .... here it is before I painted it.
Here's a few things I know. My donor car was a 97 Talon. Originally it was an auto, someone swapped it to a manual, so the trans and T-case where not original. Other than the Transmission code I provided, I don't know what year car they came from, other than obviously not being a 97-99 b/c the T-case has a 1.090 drive ratio. The transmission I bought (with the same code) the owner said came from a 95.
So, here are my questions:
Can anyone shed light on why I have 2 transmissions with the same code but two different spline output shafts?
How is it that I have a T-case w/ 22 splines that's not all aluminum? (someone swapped parts maybe?)
How hard is it to swap the output shafts on the transmissions since I do have the correct 22 spline sitting on my garage floor?
Is it possible/easier to track down a 23 spline female shaft and swap it into my current T-case? Is that part even available separately?
Is it easier to just get a whole other 23 spline 90-96 T-case?
I know it's my fault for not actually counting the splines before getting this far, but I was so focused on making sure the final drive gear ratio was correct and knew that my T-case wasn't all aluminum, I didn't even think to look at the splines. Needless to say I'm a bit frustrated as I thought I was just a few days/week away from finishing this project. Looking for input / thoughts.
Thanks.
As far as T-cases go, it has been my understanding through research that 89-90 T-cases had a 22 spline count and where in an all aluminum housing. The 91-99 all had a 23 spline with the 97-99's having the different gear ratio on the output. Unless I am crazy, my T-case is not all aluminum .... here it is before I painted it.
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Here's a few things I know. My donor car was a 97 Talon. Originally it was an auto, someone swapped it to a manual, so the trans and T-case where not original. Other than the Transmission code I provided, I don't know what year car they came from, other than obviously not being a 97-99 b/c the T-case has a 1.090 drive ratio. The transmission I bought (with the same code) the owner said came from a 95.
So, here are my questions:
Can anyone shed light on why I have 2 transmissions with the same code but two different spline output shafts?
How is it that I have a T-case w/ 22 splines that's not all aluminum? (someone swapped parts maybe?)
How hard is it to swap the output shafts on the transmissions since I do have the correct 22 spline sitting on my garage floor?
Is it possible/easier to track down a 23 spline female shaft and swap it into my current T-case? Is that part even available separately?
Is it easier to just get a whole other 23 spline 90-96 T-case?
I know it's my fault for not actually counting the splines before getting this far, but I was so focused on making sure the final drive gear ratio was correct and knew that my T-case wasn't all aluminum, I didn't even think to look at the splines. Needless to say I'm a bit frustrated as I thought I was just a few days/week away from finishing this project. Looking for input / thoughts.
Thanks.
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