Output shaft replacement without tranny pull: EASY

[massstealth]

Well i finally got it fixed. All i did was pull the little plate off, pull the springs and ball bearings out. Made sure i could shift into 1 + 2. Left it in neutral. Reinstalled the ballbearings and springs. Made sure I put the cover on the right way. It does seem to be position sensitive because the recesses where the springs lay are different depths.

Thanks to AbsurdParadox for the tips. I thought I was gonna have to pull the trans out for sure. Thanks to Kormex for a quality part and some tips over the phone.

Bob

[AbsurdParadox]

Glad to hear it worked out man! And its good to know I really helped someone out.

[AbsurdParadox]

Okay Norm, why do you keep posting and deleting it...?

E-mail me the pic of the bearing at t_nosaj@hotmail.com, and I will see if I can identify it.

[Norm]

Couldn't get the photos to attach. Emailed offline.
Thanks,
Norm

[Hi-Rev]

I know I'm bringing a post back from the dead here. I just wanted to add a few tips of mine from doing a output shaft replacement without pulling anything. Reason is, I could'nt find any of this stuff before I did it and consequently some of it became a real pain. Also, this is not a procedure, just some tips.

1. Don't remove the retainer bolt on the side of the transmission cover. Its on the top left. If you do you will be finding parts and putting them back together as I did.

2. The case can be extremely hard to get off the input shaft. Prying and tapping the allen bolt don't always work. I had to beat mine a lot to get it to finally come off.

3. Reinstalling the VCU is a pita. There are a lot of gears that must line up the insides won't slide all the way in the case. I had to keep pulling it out a little and rotating it before I finally hit the right line-up. If someone else knows a easier way then maybe they could post up.

Good Luck.

[TsunamiStealth]

Is there a way to do the input shaft also or this will just work with the output shaft?

[Hi-Rev]

I don't think you could possibly do it without dropping the tranny. Anyone else know for sure?

[massstealth]

I would say no. I am quite sure the gears are pressed on.

I agree with #1. The bolt seems to align that plastic swingy thing in place and thats it, doesnt hold the cover

#2. yes, very difficult. Took like 3 hours and a call to Kormex I put that hex head bolt back in and used a large socket w/hammer.

#3 Mine just slid right out and in like butter

[MustGoFaster]

Haven't read the thread but all you have to do it lift the lower control arm by the ball joint with a jack and you will be able to get the big long bolt out. If that's already been posted sorry.

[cbatters]

About to toss in a new transfer case / output shaft. (xfer case finally started leaking due to a crack after 193k and is being replaced for free under the safety recall.)

Directions in this thread mention the cover plate with three balls but the site with the photos / directions don't.

I'll be doing this at MassStealth's shop and he has first hand experience repalcing an output ahaft so it should go smoothly. Looks like the hardest part is getting the case cove off.

Any guesses on how long it should take just to remove / reinstall the output shaft from the tranny? (I know I can have the xfer case on the ground in under 30 minutes now that the exhaust and xfer case have been greased correctly when I did my clutch job.)

I'll keep track of time and any tips to pass along.



Clint