1G Output shaft FUBARED

[-red97rum-]

How's it going. I recently picked up an awd automatic car and I'm in the process of doing the swap to my manual car. I was pulling the trans last night and when I pulled the t-case off I noticed something odd. The output shaft has quite a bit of in and out play, I'd say more than a 1/4 inch and it looks like the splines are heavily worn. Now on a 5 speed I know that means the thrust washer in the center diff is f*cked.. The coupler's splines on the t-case look kind of flat as well. It's weird though, the splines are kind of flat but it looks like there is enough "meat" on them. Here's what the output shaft looks like, I drew an arrow pointing to the area of concern.

You must be logged in to view this image or video.

Upon doing some searching I've come across a couple threads where people have had the output shaft come out of the trans with the t-case. Some people said it was normal, others said there is a retaining clip that wears away with time and it's no big deal. I'm not able to pull the output shaft out of my trans - or at least not easily. Anyone have any pointers on how to get it out? I've pulled one out of a 5 speed but the auto is totally different. Well I guess I have a few other things to do now when the trans is out of the car..

1. Source a new output shaft, maybe IPT has some spares?
2. Buy another decent t-case
3. Rebuild the center diff or weld it, not sure yet.

Any help is appreciated, thanks guys.

 

[92EagleAWD]

Im not sure HOW different the autos are, but in the MT that output spline is only held in by 1 small ball bearing, and the ball bearing/s are held in place by the viscous coupler. If you take the viscous coupler off and pull the ball bearing out with a magnet the output spline will literally fall out. I swapped the spline on my tranny so i didnt have to buy another transfer case when i replaced it.

 

[-red97rum-]

You're right about the 5 speeds, I've done that as well. Supposedly the vc is behind the center diff on the autos and is quite the pain in the ass to remove. I'm probably going to pull the end cover off the trans today to have a look for myself.

 

[GDNF2ET]

I have a couple auto-shafts in storage and a couple spare trannys too, all of the shafts look like that...Your good
BTW: They have been discontinued for years..

 

[-red97rum-]

I have a couple auto-shafts in storage and a couple spare trannys too, all of the shafts look like that...Your good
BTW: They have been discontinued for years..

You sir are the Effin' Man! Made my day just now! I was all depressed too because the tranny fluid was clean and when I test drove the auto car in "manumatic" mode a couple weeks ago it shifted beautifully! I mean the auto car only has 114,000 miles on it.. So it looks like I will move forward with the swap then.

It's funny because my buddy Hugo (boosting_laser) was telling me it looks like it's supposed to be that way. But with my luck, and dealing with only 5 speeds, I thought for sure I was hosed. I'll probably just run the stock center diff for now since I tend to drive the car on the street quite a bit.

Just need to have the converter re-stalled and install my new end clutch kit and go for it.

 

[slowgsr]

Shaft is fine. mine looks the same, so does my spare.

 

[4pistons]

Look close at your picture. See all the filings right under your red line?? That is classic illustration of center diff failure.

The output shaft should not move more than a few thousanths. When it does move in and out it starts filing itself to death.

I don't think a new shaft has the cut down splines like that, but I've never seen an Auto output shaft. I've only had TWO go bad on my 5 speed!!

Rick - '91 GSX

 

[black_gst]

get that car running already drags are in 4 weeks!

 

[-red97rum-]

Look close at your picture. See all the filings right under your red line?? That is classic illustration of center diff failure.

The output shaft should not move more than a few thousanths. When it does move in and out it starts filing itself to death.

I don't think a new shaft has the cut down splines like that, but I've never seen an Auto output shaft. I've only had TWO go bad on my 5 speed!!

Rick - '91 GSX

Hey Rick, that's exactly what I thought and the reason I made this thread. It threw me off though because the splines are nice and square, not saw blades. Come to find out, all the auto output shafts are like this. It's just in my DSM nature to automatically assume it's screwed and needs to be replaced - as that's usually the case.

get that car running already drags are in 4 weeks!

Yeah yeah I know.. at least I started working on the bi***.

 

[boosting_laser]

4 weeks, huh? Time to dust her off & recharge the battery. Dustin, looks like you & I are the lonestars in SoCal with our autos.

 

[twicks69]

The output shaft is fine; that is how they are supposed to look on the automatic transmissions. I have several here exactly like that. As well, the auto and manual shaft do have a slight amount of play in them due to the design of how they are retained.

Run it.

 

[-red97rum-]

4 weeks, huh? Time to dust her off & recharge the battery. Dustin, looks like you & I are the lonestars in SoCal with our autos.

Shit man, I hope I can make it. I doubt I'll have slicks by then though

I still have some work to do to finish the swap.

-Change motor mounts on the 5 speed car
-Restall the converter
-Install end clutch kit
-Install trans and tcase
-Mount trans cooler and temp gauge
-Mount hurst shifter & run cable
-Swap rear ends
-Get some nitrous

It's getting there though..

 

[black_gst]

Shit man, I hope I can make it. I doubt I'll have slicks by then though

I still have some work to do to finish the swap.

-Change motor mounts on the 5 speed car
-Restall the converter
-Install end clutch kit
-Install trans and tcase
-Mount trans cooler and temp gauge
-Mount hurst shifter & run cable
-Swap rear ends
-Get some nitrous

It's getting there though..

time to take a couple sick days!