tcase help

[jbeaton9292]

Hey this is my first question i looked cant find my answer so here goes. This is my first awd and i got my trans and tcase and i cant get my tcase to slide onto the input shaft to save my life. WTF! Any help is appreciated

 

[synthetek]

Check the splines for damage, make sure the both surfaces are clean, you may have to turn the shaft a little to line it up.

 

[jbeaton9292]

I checked that and still nothing i dont get it it should just slide right on has anyone else had this problem

 

[Marc91utdsm]

Did the trans and tcase come off that car? Sounds like different spline counts.

 

[jbeaton9292]

No not from a 90 but no i counted the splines i thaught the same damn thing im so stumped i dont understand it

 

[Marc91utdsm]

Id believe its 22 spline on a 90 trans output shaft. In 91 the spline count changed to 23. Try counting the splines on the tcase again and see what you come up with.

 

[jbeaton9292]

Both are 23 i just bought the matching set ugghhhh im frustrated

 

[SrKegler]

Clean the dowel pin and the holes in the TC.

 

[99ECLIPSEGSXDSM]

Do you have an extra set of hands? It was about impossible for me to do it by myself, but when I got an extra set of hands to hold up and wiggle it back and forth it slid right on. Keep at it man

 

[AWD Street Terrorist]

With the vehicle off of the ground:

1) line up the tail shaft and propeller shaft of the driveline and slide the t-case onto the front propeller shaft paying attention not to damage the t-case seal

2) Raise the t-case up and align the drive bevel gear splines with the output shaft of the transmission.

3) rotate the propeller shaft (driveline) until the splines align on the t-case and trans output and the t-case should slip right in.

It really helps to have someone assisting you while doing this.

 

[eDeclpse92]

+1 on someone assisting you. I had the same problem. If the previous owner raced the car like mine did (thankfully he told me this when I bought everything), the splines may twist a little making it difficult to get on. I had a buddy laying under the tcase and driveshaft holding it up, while I pushed it on from the front. I used a rubber mallet and hit on that big bolt on the front of the tcase (anywhere flat will work) until it went on. I'm sure hammering isn't the haynes manual way, but it worked! I know how frustrating it is because my trans, tcase, shaft, and rear end was a matching set and it still was a pain to put together. Good luck!

edit: I misread what you put down, I thought you were having trouble with getting the driveshaft onto the tcase. I didn't have a problem putting the tcase on the trans. Sorry for the bad information.

 

[jbeaton9292]

Yeah i was trying bymyself and yes i know it was beat on some its got low miles though but you dont get a stage 3 to drive like an old lady but thanks guys ill try some of these ideas next time im with the car unfortunatly i keep it at my moms

 

[AWD Street Terrorist]

I have uninstalled>installed a transfer case twice in the past week and never once did a hammer come out. You may need to use a pry bar to separate the case from the trans, but you shouldn't have to beat on your equipment.

 

[Throwback23]

Make sure there isn't any extra dowels on the tcase and in were it mates to the tranny. I bought a t case that had both dowels and one of mine had stayed in the tranny...I didn't notice until I tried to slide it on there and couldn't get it flush..easy to overlook but if they are a set that came out of the same car I'm not sure that's the issue, are you not even able to get it started on the shaft?

 

[jbeaton9292]

No i couldnt get it started evn nothing its aggrivating

 

[NHerron]

Turn the output shaft and try again. Keep turning it until it slips into case.

 

[wparks]

Time to count the splines again. Use a sharpie and go very slow. If the trans and tcase are not both 90 chances are very good one is 23 spline. I smacked my head on the same problem- I had no idea they made the change. Had to count the splines carefully several times to convince myself- they look almost identical. Boy was it fun scrambling to find the right T-case in a hurry. Good luck!

 

[jbeaton9292]

Time to count the splines again. Use a sharpie and go very slow. If the trans and tcase are not both 90 chances are very good one is 23 spline. I smacked my head on the same problem- I had no idea they made the change. Had to count the splines carefully several times to convince myself- they look almost identical. Boy was it fun scrambling to find the right T-case in a hurry. Good luck!

Neither parts are from a 90 car i know they had the change i boight the parts from my friend that has a 93 that he pulled the trans and tcase from i seen it work in that car before i bought it so i know its right

 

[nelliott500]

Put a little grease on the input shaft to help it slide on. I also put a little bit of grease on the dowel pins because that seems to be a sticking point as well.