Need help with transfer case

[the_skin_eater]

Figured Id put this here...Pretty basic question.

Searched around...didnt help.


I took my transfer case off some months back before I pulled the engine. Well, engine is back in, and I went to put the TC back on today...Wont fit.

Now remember that this is the same one I pulled off of it originally.

It slides onto the drive shaft about half way, then stops. It wont budge. I took it off, tried again. Cleaned it out, tried again.

Went against my better judgement and tried to force it on, still wouldnt budge. Its only harder to take off...

Anyone know why this is? Do i need to have the drive shaft aligned a certain way with it? I didnt mark the alignment before hand...

The drive shaft does have a large opening, like where there should be a spline but isnt. Is that normal? And either way, why does it only go half way?
All the splines look straight to me, but I cant tell. And besides, if they wernt, the TC never would have slid off so easily when I removed it.

Just need some direction, thanks.

 

[TwoLiterLaser]

They do not have to be put back together the same as they came off. The dust shield can sometimes cause a little hinderance. Make sure you are not trying to force one of the shields to bend in any way. It should go back together like butter.

 

[the_skin_eater]

If by dust shield you mean the part that extrudes over the TC from the drive-train...Then I dont have any issue there...Its not even going that far.

I left my camera at my apartment so I cant take pics...

But ya, it get like an inch or two into it, then stops...Still got a few to go.

 

[Xeiros]

Us moliners just aren't having any fun with our cars this weekend.

 

[Karma]

You may not have the splines lined up right. I know its a bi*** to lay under the car and try and put on the t case. Have someone hold the t case, and you turb the driveshaft and pull towards the t case at the same time. It SHOULD slide in, if not make sure you didnt fubar up the oil seal on the t case.

 

[Cs4g63]

If you havent already done so it will help if you lube up the splines with some oil.

 

[the_skin_eater]

I was using a jack to hold it up as I did all this...

I did use some oil to lube it.

The spline lined up, thats why it did go in part way. Its just once it gets about half way on the spline, it stops.....

Its like something is inside stopping it, but I dont see anything.
And ya, I think I need a new seal, but its still ok. Ill get another one I spooose.
You dont think the seal could be catching on it somehow do ya??

And ya, Moline is bad luck for our cars... Then again, we now have a twin engined Talon. Gotta give props to that.

 

[boosting_laser]

Same thing happened to me last week. This is what i did:

-Sand the yoke (part that slides into the t-case) smooth w/ sandpaper or steel wool.

-Remove the end case from the transfer case & clean the part that slides into the yoke. I wraped a shop rag around a long thin screwdriver, attached it to my cordless drill & "buffed" it out.

Try the first one first.

 

[the_skin_eater]

Sweet.
Ill try that when I can. Wont be till the weekend, but Ill let you know how that goes.

Any other ideas Im still open.

Thanks.