Output shaft play

[GRace]

My output shaft to the transfercase has about 1/2" in/out play. I know there is supposed to be a retaining bearing holding the shaft in but I'm not sure if there is another problem because of the play. The shaft seems to be locked in, I can't pull it out, just a lot of play.

When I first got the car, the output shaft wasn't installed in the transmission. I just popped it in. Would the shaft just slide back out if the ball wasn't in there now? Do I need to worry about this output shaft play?

 

[twicks69]

Is this a 5-speed or an automatic?

The 5-speed has a detent ball that needs to be installed with the viscous coupler and snapring on the center differential outer pinion gear for it to retain the output shaft. To do this, you would need to remove the 5th gear cover, remove the viscous coupler snapring, then pry off the viscous coupler, then remove/install the detent ball, align the output shaft detent with the detent hole on the center diff outer pinion gear, then install the viscous coupler with the keyways aligned with the holes on the center diff outer pinion gear, then install the snapring. If you are having ALOT of play with it properly installed, then I would be worried about a worn out center diff (destroyed outer pinion gear oiling washer damaging the center diff cover resulting in excessive endplay and a destroyed center differential cover and gearset), excessively worn out tapered roller bearings on the center differential or the output pinion shaft (will damage the ring gear or the intermediate shaft 3rd gear from excessive endplay), or you have a damaged output shaft detent (worn out from prior improper installation).

If you are having excessive play WITHOUT being properly installed, there is a high likelyhood that you could be damaging the splines on the output shaft that engage the center differential pinion gears along with excessive wear inside the center diff causing spline galling resulting in the shaft holding itself in place. 1/2" of in/out play is considerably more than it should have. It should be around 1/8" in/out play.


The automatic center differential utilizes a circlip similar to a CV joint to retain itself inside the center differential on a detent groove. This style has a bit of in/out play also, and can simply be pulled out of the center diff if you disengage the circlip manually or by physically pulling in a quick enough and forceful enough jolt to "pop" it out.

Either way, what is the condition of the splines on the output shaft as well as the input sleeve splines on the Tcase? You may have some other underlying problems causing you issues either between center differential, TCase, or something less normal like a smoked viscous coupler that is seperating causing excessive output shaft end play.

Pull your 5th gear cover off and the TCase. Reinstall the output shaft properly and check the center differential outer pinion gear for excessive endplay.

The viscous coupler snapring is: MD720687 (1.5mm thick)
The viscous coupler detent ball is: MF540008 (1/4" diameter steel ball)
The output shaft seal (5-speed and auto) is: MD723202
The output shaft circlip (auto only) is: MD733868 (22.4mm diameter)

Any other parts in question or part numbers, please feel free to ask!

Here are a couple illustrations showing the auto (top illustration) vs. 5-speed (bottom illustration) center differential parts layouts and how it is retained inside the transmission.

 

[thetalonator]

thread a few months old but, wow very helpful. would have never understood without having my transission in a million pcs but, understanding how it works is key. guys like you make high hp reliable cars feesable.

 

[AUTOMODSGST]

I know this is old but I need some help about this matter they are talking about in and out play in my case I have no play at all is this normal can somebody help me figure this if this is ok or not
I recently swap the transfer case output shaft from 23 to 22 I didn't check the play before taking it apart =( I have a 22 spline tc any help is very appreciated the only thing that come to my head is that the little ball might not be the right size and it does not alow any play

 

[pauleyman]

The output shaft doens't ride on angular bearings or anything. Play isn't an issue either way unless you can pull the shaft out.

 

[AUTOMODSGST]

ok thanks