Transmission output shafts and a little advice please...

[KidVermicious]

Went over to a friend's to help him swap the (broken) multimode transfer case on his 2001 Limited 3.4/automatic today. The case he found to replace it came off a '97 manual truck.

Hit a big big snag. When it didn't slip on like we thought it should we got a little excited trying to force it, and then when we decided something was wrong and pulled it off, we found that a coupler between the two shafts came off the tcase and is now stuck on the trans output shaft. And now that I take a close look at it, it looks like the splines on the tcase output are the same count but much wider than the channels on the inside of that collar? I'm worried that we might have jacked up his transfer case output.

So what have we run unto here? Friend did his research and thought this thing should bolt up, but is there a difference in the splines on some of these transmissions?

 

[Singtoe]

they should be same.

Get a puller and pull the coupler off. Look for an indexing mark or damaged splines.

With the coupler out, by hand , place it on the transmission output shaft and spin it till the teeth align up and push on.

Bolt on the transfer case.

 

[KidVermicious]

Thanks Singtoe, we'll try that.

 

[KidVermicious]

Victory! That collar is a tight tight fit in the bearing, too tight for us to line it up well enough to seat with a 70 pound transfer case attached to it. We seated the collar on the transmission output shaft first, then lined up the tcase and used some extra long bolts to pull it into place.