1G auto output shaft comes out with transfer case

[er82]

I'm trying to remove the transfer case from auto transmission but the output shaft comes out with it. There isn't enough room to pull it all out while the trans is still in the car. Any ideas on what to do? Is this normal? The repair manual doesn't mention this in it. The reason to pull it because of severe grinding noise coming from that area at slow speed.

 

[blktalon3]

It's not supposed to come out with the TC but sometimes it does. There's a ball bearing that's supposed to be holding it in. I've always just tried to work
It out of the transfer case once I could get a good grip on it and then push it back in the trans once it's off.

 

[mondale]

I have found that if you support the xfer case with a floor jack right in its center then wiggle the tail and front of the case back and forth it will come off without the shaft coming with it. Don't jack up with a lot of force, just enough to take the transfer case's weight off of the output shaft. It binds at the transfer case input splines because after you wiggle the case off of the dowels on the transaxle, the full weight of the transfer case is leveraging on the trans output shaft, causing it to bind in the xfer case input splines. Worst case scenario you have to grab the part of the shaft that you can see (if it is coming out with the xfer case) with a vice grips and leverage it out of the xfer case by using the case as your fulcrum point. Put anti seize on the splines going into the xfer case next time.

 

[er82]

Thanks for the replies. I used vice grips for leverage and it came out about 1/4". Though the vice grips are damaging the outer splines. I will try to wiggle it some more before I attempt to take it apart.