98 GSX Output Shaft Removal/Install

[2gGSXEclipse]

Alright guys heres what i got! I locked up the transfercase and it spun the splines on the output shaft. I got a new output shaft and seal from Shepard Trans today (23 splines) Ive been researching on here for an hour about removing and installing but most lead to dead links from before. Im trying to see what im getting myself into. Ive done minor trans work before and I know I can do this. Just looking for some advice and if anyone has a link on how to do this step by step. Any help is great and appreciated. Thanks guys

 

[FLASH1970]

There's a good write up on a 2g trans rebuild on VFAQ. If you get stuck, take some pics and post them up. I've taken apart and assembled a few trans' so I'll help answer questions I am able to.

Subscribed.

 

[2gGSXEclipse]

There's a good write up on a 2g trans rebuild on VFAQ. If you get stuck, take some pics and post them up. I've taken apart and assembled a few trans' so I'll help answer questions I am able to.

Subscribed.

Thanks man....I will look into the VFAQ! I will be doing this tomorrow on my down time at work...so if I get stuck I prob wont beable to post pictures up till tomorrow night. But I REALLY appreciate the help and if i do get stuck i will post pics. Thanks

 

[FLASH1970]

You live in Island Lake right? I might be able to swing down this weekend if you get totally stumped with this.

 

[twicks69]

Are you certain that your center differential didn't get damaged with the transfer case failure?

As for installing just the output shaft, do the following:

Use a 14mm socket and remove the 5th gear cover using a prybar between the intermediate case section and the drain plug. It should be an easy removal.

Now, don't lose the reverse gear synchro, and the reverse wave spring (wave spring is attached to the 5th gear cover by two little orientation tabs.

Use a snapring pliers and remove the viscous coupler snapring.

Remove the viscous coupler using two pry bars to evenly remove the viscous coupler. Don't lose the detent ball when removing the viscous coupler.

Pull the output shaft out.

Install the new outpus shaft, install the detent ball and install the viscous coupler and viscous coupler snapring. Then reinstall the reverse synchro, clean and gasket-seal the transmission case flange with an RTV silicone sealant. Bolt back on the 5th gear cover.

 

[2gGSXEclipse]

Didnt have much time to work on it at all. Got the 5th gear cover off..got the VC off...got the output shaft out.....but then lost a ball But not so sure now??? Is there only suppose to be one ball or two? I have 1 original and went and bought another. Didnt put it together. Had to much work to do!

 

[donniekak]

Didnt have much time to work on it at all. Got the 5th gear cover off..got the VC off...got the output shaft out.....but then lost a ball But not so sure now??? Is there only suppose to be one ball or two? I have 1 original and went and bought another. Didnt put it together. Had to much work to do!

1 ball, 2 holes, strange design. It was as if they wanted people to think they lost something.

 

[twicks69]

1 ball; 2 holes.

I occasionally have a customer's transmission with 2 balls, but it doesn't matter if you use 1 or 2. You require one either way though, as it retains the output shaft.

 

[2gGSXEclipse]

O alright. I got 2 now. Yea I had th diff checked at by a professional shop and they check clearance and all that and said it was good. Took the day off tomorrow and I will be able to get it back together...still only have till noon since I have school but should get it together and atleast the new clutch in and trans bolted up. Flash I appreciate the help should he fine though...might need help with my ceddy mod soon but that's a diff story. Thanks for th help guys.

 

[4pistons]

Did you remove the trans from the car? How did you get the center diff to a shop? What did they check? Did you change the input shaft in the Xfer case, too?

Did the output shat look like this?

<img src="http://www.dsmtuners.com/gallery/files/7/9/2/7/failed_shaft1.jpg" alt="Failed Output Shaft" />

Rick - '91 GSX

 

[empie1]

any news on how this turned out?