Output shaft replacement without tranny pull: EASY

[Import Power]

Originally Posted by stealthxtreme4

How much is a 300M output shaft, and where do I get one? I found this thread by searching... but will keep searching...

I would like to bring my VR-4 to the track this summer and NG but don't want to end up like so many others and snap it. I'm harsh on my car. I won't savor any mercy off the line.

Direct from www.markwilliams.com-they are about $600

[Greenstealth]

Originally Posted by Imp Pwr Online

Direct from www.markwilliams.com-they are about $600

This would be a good thread for the "how to section"... Too bad id doesnt exist.

[massstealth]

Originally Posted by AbsurdParadox

Alright, I've seen many posts and questions in the last year or so about doing the output shaft without pulling the tranny. I just installed my 300M shaft, so I thought I would offer some tips.

First of all, let me credit JRC - http://www.vr4stealth.com/output_shaft.htm and whom ever made this page - http://hireznet.com/swap.htm. I probably wouldn't have tried it without their help. EDIT: Also wanted to give props to Sean (Internexus) who helped out a lot as well.

Now let me just tell you. Its easy. I'm not going to give a full out guide to doing it, as those two sites above are available. However, I have some good advice.

1. You do NOT need to remove anything suspension or drive train related other than the transfer case and the passenger side wheel.

2. To get that allen bolt out that sits in your input shaft, you can use a crowbar to hold the flywheel in place through that access hole on the front (of the car) side of the tranny.

3. Before pulling the tranny cover off, remove the the little plate that holds the the three balls and sprins in. This will make removing the cover easier. You may want to place a towel under the tranny when you pull the tranny cover, so you don't lose the balls if they fall (mine didn't).

4. You will probably have to hammer the cover off a bit. Take it easy, and use some soft wood or soemthing to wedge in one side while you hammer on the other to provide some better leverage for you.

5. Once you think you have the cover's dowels disconnected, the input shaft is still probably holding it on. Stick the allen head bolt back in the shaft and give it a few taps to free it from the cover.

6. Since you didn't remove anything suspension related, you can NOT remove the super long bolt at the lower left corner of the case (its too long to clear the A-arm). Just swivel the case cover on this bolt.

7. You may have to pry the gear that hangs over the VCU to get it to clear so the VCU cap can come off. At first I was prying on the gear, but Internexus (Sean) realized we can just stick something in the end of that shaft and pry that way.

8. Don't be too worried about pushing the pins in the VCU cap too far in. You have a long way to go before they'll fall out.

9. Use some RTV when reassembling.

10. Tighten everything up evenly when putting the case cover back on!

Let me know if you have any questions. Again, for a full procedure guide, see the two I listed above.

In step 3 where you say to remove the plate that holds the 3 balls and spins in, where is this. I am trying to remove the cover and was thinking the dowl pins are rusty and preventing removal. I can get the cover off about 1/16 " at top and 1/2" at bottom. Is this plate located on the front side towards the top? Any help appreciated.

[AbsurdParadox]

Hmm its been a while, but if you're looking at the back case of the tranny, it should be on the side of it, on the right side. These balls are what keep it in gear, basically. If you don't remove the little cover (look for a piece with only two bolts on it) the cover will be EXTREMELY hard to remove.

[massstealth]

Awesome, thanks.

[Show Killer]

If you happen to lose one or more of those balls let me know. I lost 1 of mine so I bought a box of 50. I have 49 left over !!

[AbsurdParadox]

Hahaha 49 left over. That's damn funny!

[massstealth]

Well I thought everything was going smoothly. Got the new 25 spline in. Went to start it and go for a test drive. The shifter will not go into 1st or 2nd gear position. All others work fine, 3 4 5 reverse. What could I have messed up. Im almost ready to give up on this car. I am assuming Im gonna have to remove the end cover again. Please help me.

[AbsurdParadox]

I would pull that side plate off that holes the three balls in, pull them out, and esnure you can run through all the gears that way, and then ensure its in neutral when you put it back on. Maybe you're getting stuck in two gears at once (1/2 is already engaged, and then you're also able to go to the other gears). Its hard to say, but it could just be something simple as your cables are getting caught on your wiring harness or something, so check that first, of course.

[massstealth]

Oh god I hope its that easy. I will try that tomorrow. I dont think its anything interfering with the cables, i didnt even have the hood open. Thank you thank you thank you

Bob