Transfer Case?

[Doug Mercer]

I just rebuilt a DOHC Turbo engine for my 1990 DOHC TSI AWD talon. The engine runs smooth and great. I pieced everything back together. I made a mistake with my clutch so I fixed that because I had a gnarly vibration in the front end. Replacing the clutch made the vibration go away. Although i still have this disgusting grinding noise when i accelerate, while in motion and from being still. I took the transfer case from another talon i had i beilieve it is a 90 DOHC Turbo AWD as well but that transfer case is either broken or the wrong spline. Im not sure if the spline being different would make it slip so sevearly? Ive put in so many hours this past week and ive gotten almost no where I drained and refilled my tranny fluid as well and it made no difference...

 

[talondave]

You could have the wrong tcase! The 23 spline tcase will slide over the 22 spline out put shaft and it will just free spin inside the tcase, causing bad clutch like slipping!

 

[Doug Mercer]

You could have the wrong tcase! The 23 spline tcase will slide over the 22 spline out put shaft and it will just free spin inside the tcase, causing bad clutch like slipping!

Could the splines be different from the same year ? :S would that explain why is was kind of easy to put on too? or wouldnt that make it more of a bi***?

 

[And_44]

Could be differnt. A previous owner could of swapped the Tranny and Xcase for a differnt year and spline count.