95 gsx transfercase problems

[eclitz88]

ok i just got a 95 gsx for 3500
it needs a new transfercase because the gear oil was leaking out from the bell housing and the pinoin bearing and there was a bunch of metal shavings. so i went to pull out the transfercase and the output shaft that comes from the tranny came out with the transfercase. therefor the oil pan is in the way for me to drop the transfercase. how do i prevent that shaft from coming out with the transfercase? and also the is a metal ring just hanging on that shaft behind the flywheel. what could this be?. im kinda new to this but i have a lot in working on cars. thabks all that reply and sorry if i miss spelled any words. im at work and had to type this up fast... thabks again!

 

[iceman510]

Been awhile since I have been in the tranny, but that shaft should be retained inside by the viscous coupling IIRC. You will need to use penetrant on the case where the shaft is stuck, as it is likely rusted in.

The metal ring sounds like it is possibly the remnant of the seal that is located there. Not sure what exactly the 95 seal looks like at that location.

 

[93AWDDSM]

Just went through this, the retaining ball in the end by your VC(Viscous Coupler) is most likely gone(my output shaft used to come out, caused a pain in the ass for pulling the T case). The way to go about this would be try to wiggle the transfer case off of the output shaft splines, up, down, smaller wiggling movements then once off your shaft can go back into its spot. Once that's done you can pull the 5th gear case cover on your tranny and pull your VC and under that you will have a spot on the output shaft for a 1/4" steel ball that sits in the end and prevents the shaft from coming out. reinstall the VC/ 5th gear case cover and you should be good(make sure the splines on your shaft are intact) You can search for a step by step write up of it, I gave you basic outline what to do.

edit: metal ring might be that output seal leaking or completely torn apart.

 

[eclitz88]

thanks iceman. where r u from in illinois?
and 93awddsm thanks for taking the time to help me out and puttin me in the right direction. i have the service manuel for the gsx. should it show the 5gear cover removal?

edit: i found out how to do it.

ok i almost have the t case off. the bearing that was on the output shaft/tcase side. was gone. it was so hott it even melted the rollers of the bearing on to the outer bearin ring. now im stuck. i cant get the sleeve off the output shaft. i think im either going to dremel a slit thu that sleeve or use a torch to aply enough heat and air hammer it off. my problem is i cant hold the output shaft towards the trans and hammer the t case off. any suggestions would be helpful. and how exactly is the output shaft supposed to stay in the transmission? and what splines do I count to know what transfer case I need to buy. ? thanks again to everybody that has helped me out.
.
edit i should have looked it up but i gues all 2gs are 23 spline

 

[Dustyaa]

I have the same issue. After I cut the inner bearing off the shart I found that the shaft splines were twisted on the end. Is there a way to remove this shaft without dropping the trans? Can I remove the cover on the passenger side of the trans to get to the retainer? Is this the 5th gear case cover?

 

[Dustyaa]

Got shaft from core trans and new tcase. All back together and working well