Transmission output shaft......short?

[Shortbus40]

Hiyas-Just did a bearing replacement on my 79 4 speed transmission.I'm fairly confident I got it back together correctly, it shifts smoothly through all gears.I only removed transfer case as it looked new and had 0 metal flakes,shards in its bottom.Re-installed everything and drove her around the block. Reverse felt kind of odd,like it was in 4 low,kind of grabbing.So- started poking around shop and found spacer for between transmission and transfer case. Joy. Removed transfer case only, installed spacer between it and transmission,and re-assembled. Now there dosent seem to be enough out put shaft to allow staked nut to snug up and clear nose cover. It appears to need another 1/8" or so to clear cone.If I overtighten the nut,everything locks up and I have to pull output shaft out of tranny to free everything. (just a rap w/a mallet-not really out)I know there are a lot of variables here, but I was hoping someone else might have been through this. I have found several threads with different woes concerning trannny and transfer joining, but none like mine. Am I in over my head?- absolutely. Any input would be appreciated.

 

[Pin_Head]

There are two spacers on the output shaft: One between the tranny and the transfer input gear and one spacer between the input gear and rear transfer bearing (which replaces the PTO gear). The first one is shorter than the rear one. Did you get the wrong spacers or put them in the wrong order? Another possibility is that the rear transmission shaft bearing is not fully seated on the transmission main shaft.

 

[Shortbus40]

I think I mis-understood the haynes book diagram,and have the main input gear reversed.Looking at this sor pic,the raised side of the gear points out of the transfer case, towards the tranny.(piece # 10). I will switch it in the a.m. and post results.

 

[65swb45]

Now you WILL have to clean out your transfer case. Installing the gear backwards will cause it to rub on the housing, creating metal shavings inside the case.

Best

Mark A.

 

[Shortbus40]

Yup-that did it-the raised part of the input gear fits into a recess in t-case,allowing more shaft to be exposed and nut to fit. Not much damage inside case,just a little shiny where it rubbed.I had to drain everything anyway. I will say that sliding the gear over the shaft in a dangling t-case was crazy hard. Bolted evertthing up, pumped in oil (a little 4.00 pump that goes on a gallon jug was a good investment from parts store) and off we went. It dosen't roar like it used to at high rpms. I'm not scared to go over 50 now.Happy. Thanks to all for advice!

 

[Pin_Head]

The tip off for the proper orientation of the gear is that it has a smooth precision ground sealing surface for the input seal. It wouldn't make sense to finish this surface if all it did was get exposed to the gear lube inside.