T-case, output shaft ?

[Dominicanodsm]

I am doing an oilpan gasket job and having some trouble getting the transfer case off. Transfer case was just replaced for a brand new one from the chrysler dealer free(thank God for recalls). I got all the bolts off the t-case and began to pry it off but it seems that the output shaft comes out with the t-case, cant get it all the way off b/c the oil pans in the way. When I started to pull it seems that the t-case is stuck to the shaft. Also all the gear oil was coming out my tranny from where the shaft comes out from. Please HELP!

 

[Sleeper-GSX]

did you take the down pipe off, thats makes for easier removal. there are 5 bolts (4 long and 1 short) to take out, and you have to pry the t-case off with a screw driver or something b/c it rest on dow pins. after you pry it off it should come right off of the drive shaft. its a pretty sraight foward removal if you use the chiltons book.

 

[Cesar]

Be careful, I was on a crawler underneath the car and it (t-case) almost landed on my head.

 

[Dominicanodsm]

Removed the downpipe and the drivers side crossmember. The problem is that the t-case doesnt just wanna pop off it seems to be stuck to the output shaft from the tranny, and to top it off the output shaft comes out with the t-case as I pull it out! Is that normal!! I did follow what the chiltons book said and stil the f**king thing doesnt want to come off! I called the dealer and spoke to the mechanic who did the job previously and he says he had trouble taking the old one off too.

 

[Sleeper-GSX]

dude it should not be that hard, after you pry it loose a little bit the only thing stoping it is the splines. but it should still come right off. you might have something broke in there.

 

[pneumo]

That's definatley not the way it's supposed to come off. The center shaft (aka output shaft) should be held in place by one little ball inside the center diff/VC junction. It seems like you might not have that ball in place.

It's easy to get at the other end of the center shaft. Basically, you remove the tranny end cover, remove the C clip that holds the VC on, remove the VC, and there it is. You should see the end of the center shaft and two holes on opposite sides of the splined shaft that the center shaft fits around. Put a BB in the hole, and reinstall the VC. I can't remember the exact size of the BB, it might be 1/4" or the next smaller size.

 

[Sleeper-GSX]

what??? are you serious, you have to take off the part of the transmission to get the t-case off. i dont thinks so. i have taken my ccar to two different shops and the way i took mine off is the same way they take it off, just unbolt the 5 bolts and slip off the t-case.

 

[pneumo]

OK whatever you say.

but wait. Didn't you say the Tcase can't come off because the output shaft slides out with it? It seems to me that the last ten times I removed a Tcase that shaft didn't come out along with it. I wonder why yours came out and none of mine did?

Maybe it's because the thing that holds the output shaft in place isn't holding it in place like it should? So you gotta figure out a way to keep the output shaft from sliding out, right?

 

[4pistons]

pneumo has it exactly right. The ONLY thing that hold the output shaft into the tranny is a small retaining ball that fits into a groove on the shaft and held captive by the VC. (Sounds like John McCain!) :laugh:

The output shaft should NOT come out with the Xfer case but if that ball was not installed before or something has failed then it's going to be a bi*** to get out.

Here's what I'd try. First, drain your tranny fluid if it isn't alll over your floor already. Then slide the Xfer case and shaft out as far as you can and see if you can grip the shaft with some channel locks and push it far enough back in to drop the Xfer case. Be Careful! Do not grip any shiny bearing surfaces.

If that doesn't work, push the Xfer case back up to the tranny where it was, remove the tranny end cover and VC. See if you can install any kind of temporary retaining ball in the groove and put the VC back on and then try to pull off the Xfer case.

Because the output shaft seems seized in the Xfer case and it slides out of the tranny easily, I suspect you have some kind of center diff failure. If that's true you're going to have to drop the trans and take everything apart.

That was my third option! :thumbdown

Rick - '91 GSX On my 3rd output shaft and 2nd center diff.

 

[Dominicanodsm]

I dont really think the center diff failed cuz the car waz working fine after the t-case recall. I think the ### that worked on the car at the dealer left the ball out and somehow seized the shaft on the t-case. Is there any tricks, or special tools to remove seized objects, ived tried everything including vice-grips and a porta power, the viceys keep coming off with the pressure no matter how tight i put them. Also when i try to put the shaft and the t-case all the way in it seems that it gets stuck on something right before it could go all the way in. Also could the ball still be in there causing it not to go all the way in, and i heard the car will run fine without the ball(other forums)?When you say VC do u mean viscous coupling? How do u remove the tranny end cover and VC? Please help, very low on funds and will attempt on my own(with a friend).

 

[4pistons]

I dont really think the center diff failed cuz the car waz working fine after the t-case recall

A failed or locked up Center diff doesn't mean the car won't move. It means the parts inside have seized and quit operating properly (causing rear tire skipping) and it would only be a matter of time before something else failed that would cause the car not to move (failed splines on the output shaft) or something actually broke and damaged internal tranny parts (side gears, spider gears, etc.).

I think the ### that worked on the car at the dealer left the ball out and somehow seized the shaft on the t-case

R&R-ing the Xfer case does not involve taking anything apart on the tranny or messing with that retaining ball. I doubt he did it.

The first time my center diff failed was right after the recall and when I asked if the tech noticed that the output shaft splines were worn he said yes but that isn't covered under the warranty, and really has nothing to do with the Xfer case recall, so he did nothing about it. Rat Bastards!

could the ball still be in there causing it not to go all the way in, and i heard the car will run fine without the ball(other forums)

I doubt it. When it comes out it falls away from the shaft and wouldn't jam it up.
Your car will run for without that ball but not fine, and not for too long. That ball keeps the shaft from moving laterally. (side to side, in and out of the Xfer case) When it does, it starts to file off the splines on the end inside the Xfercase under acceleration/decelleration and pretty soon all you have are shiny smooth "humps" and no more splines! This is also what happens when the side gear shims (thrust washers) fail in the center diff. The extra play then allows that laterall movement and POW! One day you got no go!

When you say VC do u mean viscous coupling?

YES

How do u remove the tranny end cover and VC?

That's probably the easiest part! You don't even need to remove the tranny. The end cover is on the passenger side. Remove all the bolts, noticing which lengths go where, and pry the cover off. The VC is the large, solid, round part near the bottom. Remove the snap ring that retains it and pull it off. BE VERY CAREFUL TO WATCH FOR THAT FALLING RETANING BALL! Put a pan underneath to be sure. I think there are two holes for it and it could be in either one.

Good Luck!

Rick - '91 GSX

 

[Leitnin]

id like to reiterate. watch out! that damn thing is heavy. don't go prying with it above you unsupported. Its a lot heavier than it looks.

 

[TalonspoolAWD]

I rebuilt My tranny and i think that it was missing the output shaft retaining ball. Ever since i put it back into the car it leaked fluid and i think that it was coming from the output shaft. Since the bellhousing was wet inside i think that maybe the output shaft was moving in and out and causing it to come out enough so that it does not seal around the shaft. If the output shaft will move without the ball in there, MY ? is will it move enough so that it will leak fluid. I have replace every new seal in this tranny and the only thing that was forgot was that retaining ball that holds the output shaft. I figure that it was weird that the shaft slid out with the TC.
Thanks
Tom

 

[4pistons]

I couldn't tell you if the moving shaft is causing your seal leak but it isn't supposed to move so why not fix it? It's fairly easy, no need to drop the tranny. If you let it go too long you'll be replacing that shaft and the Xfer case input shaft. $$$$$$

I'll bet you can even find one of the retaining balls free from a DSM or tranny shop in your area.

Rick - '91 GSX ...on the third output shaft

 

[pneumo]

TalonspoolAWD, the missing ball could be causing the leak.

On the output shaft the sealing surface is 7/8" wide. The seal sits in the middle, and is about 3/16" wide. If the output shaft moves outward by only 1/4" it starts to leak. There is enough extra room in the transfer case input shaft to let the shaft move out of the tranny by a little more than 1/4". A 6mm ball fits well.

 

[TalonspoolAWD]

Hey thanks Alot. I am gonna check that out tomar. I just rebuilt this whole thing and it works great but it leaked fluid off and on. It was weird, so i am hoping i can just put a ball in there and it will hold that shaft. I am gonna have to check the movement to be sure that it is the problem because i just got a 2600 and i dont want fluid on that thing.
Thanks for the info
Tom

 

[grey]

Anyone know where to get a ball from that will work? Would Walmart or Kmart have a bb that size? Or does it have to be the ball from the dealer(part#?)?I need to fix this problem too.

 

[pneumo]

Any bicycle shop will have the bearing. Probably won't charge for it either.