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2G HOW TO: Swap AWD Transmission Output Shafts

Posted by techboy, Jul 8, 2019

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  1. techboy

    techboy Proven Member

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    A ran into a problem during my AWD swap with my transfer case having a different spline count than my transmission. After posting a question I learned that you can swap output shafts on the transmissions fairly easily. I documented the process below as I did with pictures. Hopefully it'll help someone out down the road.

    First thing you need to do is remove the outer 5th gear cover on the transmission. You can actually do this with the trans in the car. Note however, I had no axle, suspension, or control arms in the way, so it might be more difficult if you don't as much taken apart already apart as I did.

    [​IMG] 44

    The cover is held on by 9 or 10 14mm bolts. Two on the bottom are very long, the rest are all the same.

    VLF3mD.jpg

    Once the cover is off, you'll see this. The 5th gear syncro will probably fall off when you remove the cover. Don't lose it.

    O6ZvlB.jpg

    2bvDf7.jpg

    This is viscous coupler, this is what we need to remove to get the output shaft out.

    xo2jlK.jpg

    There's a snap ring that holds it in place. You'll need to get your snap ring pliers to get that thing off. It's not the easiest clip to get off.

    szJEbs.jpg

    Once you get the clip off, the coupler should slide right off in your hands, if not, get to two screw drivers and pry gently forward and it should slide off.

    iggKOY.jpg

    The output shaft is held in place by a retention ball.

    QBcYT5.jpg

    There's a spot in the shaft at 180 degrees for a 2nd one on the other side, but there's only one, don't worry you didn't lose one, just don't lose the one you have.

    I used a magnet to lift the one out.

    h7VFRO.jpg

    Once you remove the retention ball, the output shaft will slide right out the opposite side.

    HueAZo.jpg

    Here it is completely removed.

    nJ4VYq.jpg

    Here's both shafts side by side.

    22PXqF.jpg

    Up close, you can pretty clearly see the difference between the 22 and 23 spline output shafts.

    0ZnGMN.jpg

    To reverse the process, slide the shaft you want in place. Put the retention ball back in place and slide the viscous coupler back on. Put the snap ring back in place.

    9omSXB.jpg

    Now you need to put the 5th gear syncro back on. To hold it in place so it didn't fall off while putting the cover back on, I packed it with vaseline.

    qrfBJo.jpg

    W0ev19.jpg

    Time to put the cover back on. clean the flange real well from all debris. I even used a little brake cleaner to clean out the inside.

    nOVyNK.jpg

    To put the cover back on, use a silicone based RTV. I had some RTV Blue on hand, so that's what I used, you might prefer something different. I can't stress enough, you don't want to GLOB this stuff all over or you'll have squeeze out inside the transmission which you really do not want. Use a very very very thin even coat. It's hard to tell from the picture, but this is a paper thin coat of RTV.

    A0gUWM.jpg

    According to the FSM, the outer cover calls for 29ft pounds. The cover is aluminum, if you over torque it you'll crack it. If you don't have torque wrench, go buy one. Don't be stupid.

    oDQTJ4.jpg

    All back together.

    Ykfzg4.jpg

    Good luck. :hellyeah:
     

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  2. ThunderChild

    ThunderChild Supporting VIP

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    Excellent job man!

    It should be noted that you're engine is not in the car I believe, and if someone wanted to do this with the complete drivetrain in, one would have to remove the downpipe and oil pan in addition to the t-case and drive shaft. The aforementioned suspension/axle components will also need to be removed to complete the job in-car.

    Nice write-up!
     

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  3. DSMPT

    DSMPT Proven Member

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    Glad to know that you successfully swapped it. Good write-up:thumb:
     

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  4. techboy

    techboy Proven Member

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    Lehigh Valley, Pennsylvania
    Just to clear a few things up. The transmission I pulled the shaft from was on my bench. The transmission that had the shaft I needed to swap was installed already and the engine was in the car. You are correct in that I didn't have the transfer case, driveshaft or exhaust installed yet, but the oil pan does NOT need to come off. When you slide the shaft out, you have about 1-2 inches of room before you hit the bubble part of the pan where the pickup is. Kinda nice, b/c it would suck to have to remove the pan too.

    Thank you for replying to my initial thread and pointing me in the right direction. Appreciate the help. Happy to be moving forward again.
     

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  5. ThunderChild

    ThunderChild Supporting VIP

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    Excellent, thank you for the correction! I eyeballed one of mine and thought there was no way it'd come out with the pan on. Nice! :thumb:
     

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