matt720

Hey all - I have just rebuilt my transfer case since it exploded on me a few weeks ago. Finally got around to mounting it up. Everything seems to slide in fine until I get a 1/4 inch away from mating and it wont budge. Also dont have enough threads coming out on the other side to get a nut started.

Did I do something wrong? Has anyone encountered this before??

Whiplash

dunno, but first thing i'd do is check the length of the trans output shaft (to the rear of the case) compared to the depth available on the t/c (from front of case)...

JPXJMOAB

More than likely the input shaft isn't correct

freegdr

Got old case....

XJwonders

Did u pick up another t case or rebuilt the one on the jeep?

matt720

I rebuilt the old one so everything came off the jeep except for the front case half and new bearings. Shafts should go together fine..

djcherokee

The only thing i can see being the problem would be wrong input shaft. Did the new front case half come with a different input? You're still using the old one? Anything fall inside the t case input splines?

Are you jamming up against the shift linkage or anything on the body? Wiring harness falling in between the trans and case?

Photojared

Input shafts changed in 96(?). Do you still have the old front half?

Freedgr has a perfect picture. Your input shaft is probably too long and is bottoming out

matt720

Looked for any blockage and there is nothing there. Input shaft is the same(original) and the case half is the same(casting numbers are identical) Also dont have the original case its in pieces.

Seems that the shaft is hitting the oil seal then stopping. put some assembly lube on it but still wont budge. Even lightly tapped it with a rubber mallet.

Out of ideas and losing my mind!!!


Edit: Would installing an SYE affect this at all?

Dont wanna take this whole thing apart again but it looks like its going to have to happen

Photojared

Casting numbers for what? The case? Casting numbers wouldn't change.

Did your replacement case come out of a '01?

matt720

Not sure, the case was ordered from drivetrain.com based on the casting numbers.

Did different years use different case halves on the same t case?

ZJMAX

Is it the correct oil seal? Maybe the I.D. of the seal is too small for the shaft?

Max

Photojared

That's what we're saying. 95 and below cases had a different input spline count than 96+ and there were also differen input shaft lengths.

XJwonders

1991 and up have 23 splines. Except for those behind 4 cylinders.

1990 and earlier had 21 splines.

Photojared

Ok. Something else changed in 94+ (I was wrong with 95) and up np231s. i had to order a different adapter from AA for my LS swap (might be input journal or bearing size or something IIRC).