Can't Remove TC! WTF?

[InfiniteGSX]

I installed a new transmission a month ago and it was a little stiff to get the TC on, but nothing hard. I'm pulling the transmission again and I have the TC pulled about a 1/4" away from the transmission but I can't get it out any further. ITs out enough to swivel the tc around on the input shaft. But it will not slide off the input shaft!

WTF? I even sprayed pb on it thinkin I might have gotten some dirt on the input shaft when I installed it and it fused it together... but seriously? I've tried hitting it with a hammer to get it to move but I can't swing hardly at all because of a cracked wrist joint causing me alot of pain.

This is the only thing holding me back right now, What the hell can I do?

 

[2gGSXEclipse]

Two pry bars...one on both sides and pry that thing off.

 

[InfiniteGSX]

I can't hurt anything can I? I moved the tc back on and off watching where it slides onto the input shaft and the shaft is moving with it. I don't know if the shaft is supposed to have any sort of play? I'm afraid of prying on it cause its soo heavy and I don't know how to pry it away without it dropping onto the ground or me... or one of my lovely testicles!

 

[2gGSXEclipse]

You shouldnt hurt anything...the only thing i have ever seen is my transfercase actually mated to my output shaft on the trans and spun the splines together, so when i pulled my transfercase the splines of that got stuck on the trans. If yours hasnt done this it should come off rather easy.

 

[Bender]

It may be caught on some bearings/turbine assemblies. See if you can't walk it off.

 

[InfiniteGSX]

no its caught on the input shaft. i can move the tc about a 1\4 inch and watch the shaft move with it. ill try prying more when i can figure out something soft for the tc to fall on.

 

[toofast82]

Two pry bars...one on both sides and pry that thing off.

I ran into this when I was swapping to 5spd. I used two large pry bars and a friend. We had to pry the shit out of it, but it finally gave way.

 

[viperlp01]

Ya that shaft does move alittle... It has probably rusted together.. Just make sure the T-case doesn't fall on the ground/crack..

 

[Bender]

You would be hard pressed to brake a torque converter by dropping it from that low to the ground. You would just put a dent in it.

You could rip the starter gears off though with prybars if it is not coming. If you do this, use extreme caution.

Input shaft end play should be .012-.039". Anything over that and you may have a worn snap ring. It may also be worn thrust washers.. which should be replaced. Anything excessive, and the ring may be broken or gone. You would also probably have other breakage too.. like drum splines, planetary set, etc.

If you need to tear into the transmission, be sure to get the overhaul manual off my site. It will come in handy by listing all the tolerances, and torque specs.

Automatic DSM'S

 

[InfiniteGSX]

Well I'm not an Automatic tho .... And I'm kinda talking about the TransferCase... Not Torque Converter. Sorry for the miscomunication.

Its a brand new Transmission. There was no play when I put it in, but when I put it in, the TC was a little rough to get on.... It slid on almost all the way and I used the bolts to get it the rest of the way cause of the little room I had to work with under the car. Haven't had an issue with drivability, except I broke two bolts that hold the transmission on the motor because I stupidly forgot the Dowel that keeps the transmission from moving around. So thats why I'm pulling the transmission really...

 

[2gGSXEclipse]

Yea dude, i would just keep prying....i mean there isnt really much else you can do in this position. Just got something/someone to hold the xfercase from dropping when you are prying.

 

[InfiniteGSX]

MUAHAHAHAHAHAHAHAHA.... Well I just put a couple pillows under the TC and started prying on it... MUAHAHA. It started to move. So I marked with a sharpie on the shaft to see how much its moving. Well I pry on it again and get it pretty far.... GUESS WHAT! ITS PULLING THE ENTIRE INPUT SHAFT OUT OF THE TRANSMISSION!

WHAT THE FACK!!!!

 

[2gGSXEclipse]

yea something is defienetely wrong. Dk if the input shaft can pull all the way out or not, you would have to look that up. That sounds Fd up forsure.

 

[InfiniteGSX]

Now, The entire input shaft is out of the transmission.... Transmission totaled? I have another transmission, my old vin matching trans. It has no 2nd gear so I can use it for parts but wtf.... I can't get the entire TC off cause the shaft is soo long that I need to pull the transmission away while dropping the TC at the same time.

 

[Bender]

Oh. TC normally means torque converter. haha. I guess it could mean x-case as well.

Also, it is normal to be able to pull the output shaft out all the way. If you need to, drop the oil pan, and take the whole output shaft and x-case out as an assembly.

 

[InfiniteGSX]

Transmission came out fairly easy this time around with the Transfer Case still attatched. I pulled the shaft and then noticed there is a ball bearing that holds the shaft in place. So I pulled the shaft from my other transmission and installed it in this trans. Now I just gotta find a way to seperate the Drive Gear Bevel Assembly from the other Output Shaft and get a new bearing for it.

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[Fabian]

I had this exact same thing happen with my 1g when I'd pull the X-case doing the motor swap. I was able to free it up off that shaft my used a rubber hammer and a pry bar though. Funny though, cause when I posted up about it everybody thought I was a retard.

 

[InfiniteGSX]

I gotta find a awd in U Pull It hopefully with a transfer case so I can pull the part out of. I can't get it off the shaft at all.

 

[4pistons]

Buy a new one, don't try to find a used one. They are so abused it's not worth the trouble just to have it fail again.

You SHOULDN'T be able to pull the output shaft without removing the small retaining ball. Something's wrong. Where'd that ball go?? You may have cracked the Viscous Coupler in the trans by just prying the shaft out. Check the factory service manual for the proper assembly.

The problem you're having with the output shaft stuck in the xfer case may be related to the center diff being worn out. If your output shaft splines are worn you'll need to check the center diff. This will explan how it works Welding a Center Diff - How and Why - DSM Forums . Below is what worn splines look like.

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

Rick- '91 GSX