Output Shaft/T-case

[munchgsx]

HI

I have a 1991 Eclipse GSX that started has a rolling chassis. Finally got around to installing Trans and T-Case. Started car and left the driveway to start motor break in. Everything seemed fine until I step on the throttle alittle harder, then I hear a noise that sound like two fine tooth gears grinding together, and it feels like the clutch is slipping. Turned around and it made the sound in reverse too, felt like the clutch was slipping. Just got done pulling transmission and discoverd that the output shafts teeth seemed rounded off same with the inside of the t-case. I decided to count the teeth, 21 on the trans and 23 in the t-case. I need to swap the output shaft to a 23 spline shaft so that it will fit the t-case. HOW did I get the t-case on the trans is it possible, it went on without problem? I should of counted before. Would the feeling of the clutch slipping happen if the output shaft was slipping in the t-case.
Sorry this is so long I'm just alittle confused on stuff.

Thanks

[x-pride]

Are you sure it went on. I have a hard time believing that you put the transfer case on the tranny so easily if they are the wrong spline on each. Sorry I don't have any input for you. Just found it wierd that you was able to do that.

[munchgsx]

Yes it went on, seems that the output shaft had problems before hand. I took out the shaft... Can I replace the shaft with a 23 spline shaft?
If so where can I get that from?

[HKSenilyks]

Yea that seems odd that it went right on I was helping a freind of mine install a x-case on a 90 TSI and the splines where wrong, we had a hell of a time untill we relized the problem. Got the right x-case and it slid right in.

[slowbubblecar]

you should be able to replace the shaft with the correct one.