t-case install

[TimF]

I am trying to install my transfer case since 1 now and I can't get it to line up at all. I was able to with the drive shaft out and I am wondering if I can attach the transfer case then put the drive shaft in. The end right by the 8mm that holds the flywheel cover in place does not seem to have enough clearance to allow the tcase to fully sit on the trans. I can't post pics due to this is from my phone and I dont have a working computer

 

[92AWDHX40]

http://www.dsmtuners.com/forums/articles-drivetrain/224419-how-remove-transfer-case.html

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Trans & Clutch 1 - Remove Transmission - YouTube

 

[TimF]

I have watched that believe me it still does not answer anything

 

[Archer Fabrications]

Are you sure the shaft is going in the tail all the way? Ive never had a problem like your explaining, was this tcase sent off? Or new to you? Maybe its the wrong year tcase?

Then again i dont run a flywheel cover window plate dealy.

 

[SmoochDarling]

Is the flywheel cover bent or misaligned? This might cause it not to fit flush. Other than that I'm not sure what else would give you hang ups. Do you have the transmission dowels still in place? I always leave my driveshaft in, I hang it up with wire, slide the case on, pop the output shaft in and align the bolts. Fairly easy to do.

 

[TimF]

I do have the pins in. But it seems to be hitting the trans, Its the original tcase to the car, but the trans is a diffrent one. The tcase Is out of a 91 talon, and the trans is out of a 95 talon, but I was told that shouldn't matter

 

[92AWDHX40]

Are your using a 2g trans in a 1g DSM?

 

[TimF]

Yes, and I checked the tcase is the same from 91-96 so that can't be the issue

 

[92AWDHX40]

I don't know what the problem could be mines works fine with my 1g trans and setup.

 

[TimF]

I might just have to grind down the trans to make it fit.

 

[twicks69]

You do not need to grind down the transmission to make it fit.

Make sure you have the dowels installed in the bellhousing and don't have an additional dowel still installed in the transfer case. Confirm that your driveshaft yoke is not twisted by inspecting the splines. Confirm that you in fact have a 23-spline transfer case with a 23-spline transmission output shaft.

The late 1991-1999 transfer cases all fit exactly the same on a late 1991-1999 transmission case; the differences are only in final drive ratio of the transmission from 1989-1996 vs 1997-1999. The 1989-mid-1991 transfer cases are full aluminum housings with 22-spline input sleeve. The late 1991-1999 transfer cases are cast iron front housing with cast aluminum mid and tail housings with 23-spline input sleeve.

And yes, a 2G AWD transmission fits in a 1G; be sure you are using the proper shift cables and starter plate and you really don't need the flywheel inspection plate sheet metal.

 

[TimF]

It is a 23spline. I ground down the trans and tcase a bit and it slides in further but not all the way. All dowel pins are there and not doubled, drive shaft is fine. When its on the car I can't move it up or down to align the holes and it still.won't fully attach to the trans.

 

[T is for TURBO]

Something is not right. I just removed and re-installed my t-case this weekend. It took me no more than 10 minutes to take it off and no more than 10 minutes to re-install it, It's one of the easiest things to replace... Are the dowel pins in good shape? Spline shaft is straight? Splines are straight? Broached t-case sleeve splines are straight?

 

[TimF]

I cleaned on the splines on both the transfer case and the trans, the dowel pins are fine, I cleaned out the dowel pins holes ect. From what I can see there isn't anything wrong

 

[92AWDHX40]

That's weird it should only take a very short time its pretty straight forward, kinda hard to see what the problem is. Tim described the types of cases and what fits what, can you find a friend with a camera or phone to post pics difficult to undertand without pics of the case and area your having problems with. Again you shouldt have to grind anything down.