Transfer Case Removal

[yekrahs]

Ok the input shaft is stuck to the transfer case any suggestions as to how to get it off, but its pulling in and out of the tranny so that makes it that much more difficult.

 

[1stGenRocks]

I used a narrow pair of channellock pliers on mine. Grab the shaft with them and wiggle it towards the trans while pulling the tcase to the side. Might be easier with 2 people, I almost dropped mine when it finally came off.

 

[4pistons]

the metal that they used for the shaft breaks down quickly if it gets rusty on the splines

FALSE FALSE FALSE!! Please go back and read my posts at the begining of this thread a year ago, and read this thread http://www.dsmtuners.com/forums/showthread.php?t=244241

That output shaft is made from hardened steel and supports 9 second cars with over 500 hp. It does not break down quickly or easily.

What your seeing is the result of a FUBARD'd center diff where the splines have filed themselves off due to excessive play. Do not put that back together without fixing the diff or you'll soon have the same problem again.

If you take the end cover off a manual tranny you can remove the VC, watch carefully for the small retaining ball to drop out - catch it, you'll need it - and the output shaft will slide out with the Xfer case attached if you can clear the underbody.

The rust everyone is refering to is not the shaft, it's the filings from the splines. It wipes right off with a rag and you'll see the shaft is not pitted or flaking or "breaking down." The rust is the RESULT of the failure not the CAUSE!

Rick - '91 GSX

 

[yekrahs]

So I take it that my differential is bad? my problem was that the xcase was leaking out of the oil seal flush with the xcase. So if I put a new seal in am I going to be able to drive it or is my center diff bad? Whats the deal?

 

[wibblersnatch]

I ended up wedging something between them to keep it out and then using some vise grips to push the shaft back into the tranny little by little. It eventually came out but it took an 1/8" at a time. I also PBed the hell out of it.

Thats what I ended up having to do. It is definatley a PITA.

 

[wishihadatalon]

FALSE FALSE FALSE!! Please go back and read my posts at the begining of this thread a year ago, and read this thread http://www.dsmtuners.com/forums/showthread.php?t=244241

That output shaft is made from hardened steel and supports 9 second cars with over 500 hp. It does not break down quickly or easily.

What your seeing is the result of a FUBARD'd center diff where the splines have filed themselves off due to excessive play. Do not put that back together without fixing the diff or you'll soon have the same problem again.

If you take the end cover off a manual tranny you can remove the VC, watch carefully for the small retaining ball to drop out - catch it, you'll need it - and the output shaft will slide out with the Xfer case attached if you can clear the underbody.

The rust everyone is refering to is not the shaft, it's the filings from the splines. It wipes right off with a rag and you'll see the shaft is not pitted or flaking or "breaking down." The rust is the RESULT of the failure not the CAUSE!

Rick - '91 GSX

True True True. Go talk to the best in the business. Jon at T.R.E. will fill you in.

 

[4pistons]

talk to the best in the business. Jon at T.R.E. will fill you in

I have, that's how I figured out what the problem was. Maybe you misunderstood something he told you.

Again I will repeat - The rust is the RESULT of the failure not the CAUSE!

I have BOTH failed shafts from my car sitting on my workbench and NEITHER of them is rusty. After replacing them the first time the new shaft failed in about 16 months. You're going to tell me a hardened steel shaft rusted away in 16 months??? I don't think so.

I welded my center diff http://www.dsmtuners.com/forums/showthread.php?t=173481 and replaced the shafts again over six years ago. There is no rust on the shaft now, nor is there any wear on the splines.

the xcase was leaking out of the oil seal

So you were leaking oil right on the splines but they failed anyway??? How could that be if it's only a matter of rust???

So I take it that my differential is bad? ...am I going to be able to drive it...?

Can't tell you that, I don't have your stuff in front of me. If you have trashed splines your diff is going bad. Maybe you'll get ten miles, maybe you'll get 1000 miles. You won't know until you inspect it.

Rick - '91 GSX

 

[TSIMonsteR]

If you feel as though there are 6 we encourage you to post pictures to support your claims. Thanks,
Doug

BAM, back from the dead. On the AUTO T-case I just removed.... 6 Bolts, mmkay

3 on the bottom, 3 on the top. The 2 usual and an extra one hidden from sight.