Resolved 1G ATX Transfer case won't go all the way on.

[zippy22]

My transfer case won’t go all the way on and it feels like it’s bottoming out on the output shaft from the tranny

 

[twicks69]

Ok, have you confirmed you are using the correct spline transfer case input sleeve to match the transmission output shaft spline count? Have you inspected the condition of the splines on both components? Have you inspected with a flashlight to confirm that your transmission output shaft has not pulled out of the transmission? Are you dealing with an automatic transmission or manual transmission?

 

[zippy22]

Ok so I had to replace both the output and input. When they were out both fit and it goes on the splines mostly up until the last like 1/2 inch where they are a little bigger I tried to bang it in more and it wouldn’t budge but I wasn’t hitting it super hard cause I don’t want to break anything it is an automatic I got the parts from raven fabrication and told them what I needed it just stopes where the splines get a bit bigger which is making not even make it into the dowel pin

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[zippy22]

Should I try to hammer it in more

 

[jdxnc]

I don't know the auto trans but that output shaft looks to be way too far out. You don't hammer anything.

 

[dwb]

It's bottoming out on the shaft. There's about 1/2" of splines on the shaft that won't engage with the transfer case coupler. Double check that you have the correct shaft and that it is installed properly.

 

[zippy22]

How exactly would I double check that I have the right shaft

 

[dwb]

How exactly would I double check that I have the right shaft

Do you have a part number?

 

[zippy22]

No I where would it be on it

And how would I make sure it’s in all the way

 

[dwb]

Maybe check with the seller or your invoice for the PN if it was new.
On a manual trans the output shaft held in with a steel ball sandwiched against the VC and you would have to remove the top case and then the VC to inspect it. On an Automatic, I'm really not sure how it is mounted in there.

 

[zippy22]

I couldn’t find any new but I got one from raven fab and they just let me come and pick it up I live in Spokane Valley so that was the only way to get one and we looked at them side by side they were identical other then my old ones splines were shredded but all I had to do to get it out was take off the back cover that the center diff was in then pull of like a gear stick a long screwdriver in it and tap it out he said all I had to do to get the new one in was tap it in

 

[dwb]

If you matched up the old shaft with the newer one, and feel confident they match, then it's likely an install issue. I don't know a thing about autos, but I highly doubt the shaft is installed with a hammer.

 

[zippy22]

So should I just wait till somebody else knows who can

 

[TerminalTalon]

We need more pictures. Pull the tcase. Take pics of it. Count the splines. Is it a 1G or 2G trans.

 

[zippy22]

Figured out the problem I was given a 2G output shaft for a 1G.

Thank you for the help everybody.