twack
07-21-2010, 12:49 AM
Some times you need a new transmission and you cant always be picky on what spline the output shaft is to mate up to your transfer case. Like a 90 in a 92. This is a write up on how to swap the output shafts in order to be able to run what ever you need.
You can do this with the trans in the car. Its pretty easy.
If you are swapping transmissions and you had a 23 spline transmission and you want to put in a 22 spline or vice versa this is how to do it without buying another transfer case. Its easiest with your old transmission because you already have the right shaft that you can swap with. otherwise youl have to look around for a shaft,
drain trans
Pull the 14mm bolts that hold the endcase.
http://i73.photobucket.com/albums/i212/twack89225/07202012.jpg
With all the bots removed separate the endcase at the very top. It has a seal so it will need a little work to separate it.
http://i73.photobucket.com/albums/i212/twack89225/07202012a.jpg
The red arrow shows a small thin sprocket that will fall out if your doing this in car, just be careful to not lose it and know where it goes. The blue arrow shows the C clip you need to remove to access the viscous.
http://i73.photobucket.com/albums/i212/twack89225/07202025.jpg
Pull off the viscous. Push the shaft inside, out the otherside, it will come out easy now that the viscous is out.
http://i73.photobucket.com/albums/i212/twack89225/07202030.jpg
While your pulling the shaft out and once its out be careful to not loose the ball bearing that hold the shaft in.
http://i73.photobucket.com/albums/i212/twack89225/07202030a.jpg
Insert the correct spline out put shaft (careful of that ball bearing again)
Follow the directions in reverse to re assemble. I used gray RTV on mine. dont make a mess with the rtv, a good seal is all you need.
You can do this with the trans in the car. Its pretty easy.
If you are swapping transmissions and you had a 23 spline transmission and you want to put in a 22 spline or vice versa this is how to do it without buying another transfer case. Its easiest with your old transmission because you already have the right shaft that you can swap with. otherwise youl have to look around for a shaft,
drain trans
Pull the 14mm bolts that hold the endcase.
http://i73.photobucket.com/albums/i212/twack89225/07202012.jpg
With all the bots removed separate the endcase at the very top. It has a seal so it will need a little work to separate it.
http://i73.photobucket.com/albums/i212/twack89225/07202012a.jpg
The red arrow shows a small thin sprocket that will fall out if your doing this in car, just be careful to not lose it and know where it goes. The blue arrow shows the C clip you need to remove to access the viscous.
http://i73.photobucket.com/albums/i212/twack89225/07202025.jpg
Pull off the viscous. Push the shaft inside, out the otherside, it will come out easy now that the viscous is out.
http://i73.photobucket.com/albums/i212/twack89225/07202030.jpg
While your pulling the shaft out and once its out be careful to not loose the ball bearing that hold the shaft in.
http://i73.photobucket.com/albums/i212/twack89225/07202030a.jpg
Insert the correct spline out put shaft (careful of that ball bearing again)
Follow the directions in reverse to re assemble. I used gray RTV on mine. dont make a mess with the rtv, a good seal is all you need.