Transfer case install problems

[lil corb]

Here is the background: I have a 91 1G (production date of May). Transmission is brand new from a 7 bolt 1G built by Shep. Splines on the transmission output are 23 (counted by myself and a friend numerous times). Transfer case Splines are 23 (counted by myself and a friend numerious times).

Problem is when I try to install the transfer case on the Output shaft it does not want to go. I have tried installing it without inserting the driveshaft and still nothing. It does not want to insert even wiggling it up and down and side to side.

Any idea on why this is happening?

Getting frustrated

thanks in advance

 

[BIGBLAZE79]

Is one of the splines double the thickness of the rest? Did you line that up to the transfer case accordingly?

 

[lil corb]

Is one of the splines double the thickness of the rest? Did you line that up to the transfer case accordingly?

Nope, splines on output shaft and transfer case are perfect. I lifted the transfer case and looked at it from different angles as I tried to push it in the shaft and nothing. It's seems like the output shaft is too big to go in the transfer case... but that shouldn't be the case.

Any other thoughts???

I'm going to get someone else to come and count the splines. I guess it's possible that me and friend mis counted several times.

I will update once I get it figured out.

 

[tron2119]

What was your problem? The same thing is happening to me.

 

[lil corb]

What was your problem? The same thing is happening to me.

It was just an alignment issue with the splines. The splines matched up but had to play with it and adjust it up and down while pushing it in.

 

[turboglenn]

Sometimes i fnd the transfer case the hardest damn part to put backon the car and sometimes i get lucky and it just goes up there right away. For me i think a lot of it is holding the weight of the case and the driveshaft while trying to get the splines lined up.. But the last two times i've done it the first time i lifted it up there it just slid right on, I couldn't have been happier they can be tough