1G Output shaft issue (coming out of trans)

[enriquez2000]

I am having the worst luck with this car and at my wits end...

Car has not moved at all and now while tryi g to pull the tcase the shaft is coming out of trans instead... never have I had this issue. Itd make sense if I was racing but car was just put back together... idled.. had rod knock... and nkw im tearing down.

Im not sure I can pull motor and trans together with tcase hanging there so

Question 1.. what would you guys do? Im in my home garage with no lift so dropping from below is not an option

Question 2.. whats the fix? I read that I take the end case and VC off but then 1 post said auto is held in with a clip while another says ball bearing...

Just looking for answers.. im verting frustrated and need to breathe

 

[1990TSIAWDTALON]

Pull the Tcase off with the shaft attached. You can deal with it separately from the rest of the issues. When it is out you have options on what to do to get it out of the coupler in the Tcase.
It's what I'd try to do.
Has it always stayed in the transmission until now?
Crossing fingers!!!

 

[enriquez2000]

Pull the Tcase off with the shaft attached. You can deal with it separately from the rest of the issues. When it is out you have options on what to do to get it out of the coupler in the Tcase.
It's what I'd try to do.
Crossing fingers!!!

I cant get the tcase down.. not enough room. Tried to do that.. may have to try pulling whole assembly with tcase on then seperate

 

[1990TSIAWDTALON]

Man that will be a BIATCH. I do understand the clearance issue. Drop the whole front member maybe? For room to work. That's a Biatch too. You can't catch a break can you?

 

[enriquez2000]

Man that will be a BIATCH. I do understand the clearance issue. Drop the whole front member maybe? For room to work. That's a Biatch too. You can't catch a break can you?

Not this week. My shower broke and flooded the downstairs bathroom too.

Its a shit week...

I was going to pull the motor to soothe my soul now this

 

[motomattx]

Why cant you pull the cover off of the end of the transmission and put the ball back in the viscous coupling to hold the shaft and then take the t-case off?

 

[enriquez2000]

Why cant you pull the cover off of the end of the transmission and put the ball back in the viscous coupling to hold the shaft and then take the t-case off?

I saw conflicting info on if its a ball or clip... then i came across this while reading the manual... #90 says tap it in securely.

Ill try opening it tomorrow. Feeling defeated today.

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[enriquez2000]

Went and opened the cover...

No ball anywhere which is weird since John at IPT built it and I wouldnt think he would leave that out. It looks like it thould just be sitting in the case if there was one.

Also cant figure out how youd out one in... maybe its late and im not thinking but the only place to drop a .25 inch ball is in the holes of the VC and they are hidden when its deep enough to catch it.

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[enriquez2000]

Foud my answer... no ball on autos. So i have to try some magic to get it free and tap it back in. At least i know what it looks like now

Took some digging but thanks @twicks69

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[enriquez2000]

Ok for the next person that has this issue on an auto... here is what you do

Dont take the back case off.. no need and just makes a mess

Slide shaft with tcase on it out far enough to get vice grips on the shaft close to the trans. Use a rag on the teeth so you dont score the shaft.

Put a prybar between vice grips and tcase so you can push it off the end

Once off push the shaft back in and tap with a rubber mallet as per above.

Now its locked back in place. Make sure to use copious antiseize the next time you reinstall

 

[1990TSIAWDTALON]

Thank you for posting how to attack this issue for future members!
Glad it's out and you can proceed!

 

[twicks69]

Sometimes people dealing with automatic transmissions that have rusted up output shaft splines, worn splines, or gunk from metal dust and grease in the tcase input sleeve, are all issues that can cause more resistance while removing the transfer case and can pull out the output shaft on accident. The output shaft on an automatic transmission is retained by an internal circlip in the pinion gear inside the center diff. It does not have a detent ball and snap ring like a 5 speed transmission that holds in the output shaft. Like the post of mine you copied in, it simply needs to be reinserted and whacked with a mallet. It will lock in. If it does not, then the details below would give explanation.

Sometimes though with modified center diffs, especially welded center diffs, I have seen several times that the circlip has lost spring pressure from being heated up during the welding job causing it to not retain the output shaft as well, and I have also seen several that whoever welded the diff would remove the retainer circlip, not knowing that it is needed to hold the output shaft in place.

With the output shaft splines and the tcase input sleeve splines I recommend thoroughly cleaning with a wire brush and brake clean and compressed air (for the input sleeve). A ton of rust stuff is usually in there that can cause the output shaft to jam in the tcase input sleeve.

I wouldn't say using antiseize is necessary, but a tiny amount of marine synthetic grease could be used.

 

[enriquez2000]

Sometimes with people dealing with automatic transmissions that have either rusted up output shaft splines that are causing more resistance while removing an automatic transfer case this can happen. The output shaft is retained by an internal circlip in the pinion gear inside the center diff. Like the post of mine you copied in, it simply needs to be reinserted and whacked with a mallet. It will lock in.

Sometimes though with modified center diffs, especially welded center diffs, I have seen several times that the circlip has lost spring pressure from being heated up during the welding job causing it to not retain the output shaft as well, and I have also seen several that whoever welded the diff would remove the retainer circlip, not knowing that it is needed to hold the output shaft in place.

With the output shaft splines and the tcase input sleeve splines I recommend thoroughly cleaning with a wire brush and brake clean and compressed air (for the input sleeve). A ton of rust stuff is usually in there that can cause the output shaft to jam in the tcase input sleeve.

I wouldn't say using antiseize is necessary, but a tiny amount of marine synthetic grease could be used.

Excellent feed back. I did switch tcases on this last install so very likely I missed the rust on the input sleeve.

Unfortunately I didnt find your post until I took the back case off... I want to make sure its well documented as even this post someone said to fix the ball.

 

[motomattx]

I didn't know that you were actually working on an auto, the pictures didn't load for me and I missed the auto mention in the first post.

 

[enriquez2000]

I didn't know that you were actually working on an auto, the pictures didn't load for me and I missed the auto mention in the first post.

No worries! All fixed now... and this will help someone later on

 

[99dsmer4g63]

I had this issue the first time I pulled my motor. Couldn’t separate it for nothing. Mine is a manual trans though.

I was in my home garage also with nothing but my engine hoist, my jack and jack stands.

I was able to jack the front of the car up and slide the entire assembly out the bottom under the car in the passenger wheel well area.

I’m also 2g so not sure if the 1g has something that could stop this from happening but just wanted to say that it can be done without a lift as I’ve done it with my dad and I.

Glad you figured it out though. Good luck with the build and the house.

-Daniel