Question about mating SM465 to transfer case

[BladeRunner80]

I just got my SM465 back from the machine shop today and decided to do a test fit. I pulled the transfer case's input gear out (3 speed tcase) and tried sliding onto the transmission's output shaft, but it only goes on a little way......it's extremely tight. I didn't pull out the mallet yet, as I was worried I wouldn't be able to get it off if I started to beat on it.

So what's the trick to getting these two to play together? Seems like it will be a bit more complicated to try and pound it in there once I get the transfer case all put back together.

 

[Poser]

I have had the same issue in the past with the stock gear on 420/465 output shafts, and trying to fit the Orion input gear onto the output shaft of the GM transmissions.

What I found was that the inside diameter of the gear was too large to slip onto the output shaft properly, so I took a sanding wheel on a die grinder to the ID of the gears and removed just a little bit of this area and the gear then slipped on the output shaft.


Couple pictures:

 

[Poser]

1/4" die grinder 1" 60 grit abrasive flap wheel:

 

[BladeRunner80]

Thanks Poser....appreciate the tips!

 

[kulangot]

Here is another way, put the gear in an oven for about 30 minutes and put the adapter shaft in the fridge for the same amount of time.

You might be surprised as the two parts will pop right together with a few love taps of a brass drift.

The good thing about the way that Poser did this is you can take it apart again. If you use my method, you'd need a gear puller.

I learned this from the rebuild manual for BMW motorcycles where it's a standard procedure for assembly.

-Stumbaugh

 

[Poser]

Here is another way, put the gear in an oven for about 30 minutes and put the adapter shaft in the fridge for the same amount of time.

For pieces requiring an interference fit; these output gears are a supposed to be a slip fit. The reason you need a puller to separate the transfer case from the transmission in many instances, is because of grime that is in the splines on the transmission output shaft hampering the gear(s) from simply slipping off the output shaft.

 

[BladeRunner80]

Poser, thanks again. The flap wheel sander did the trick! Just waiting for some new gaskets to show up and I should be ready to roll!