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Back story, building an '82 toyota pickup, 5-speed, into a trail rig, plan on 5.29 gears, dual case, and 35" KM2's.
I just finished breaking down a t-case from a 1980 pick up for the donor in my dual case set up, when I went to plug it into my transmission, it was very tight and after tightening down the 6 14mm bolts, there was a "ping" noise that sounded like it came from the t-case/tranny. I tried spinning the drive line flanges but they seem to be stuck or very very hard to turn. I thought I may have gotten the bearing in at a weird angle and pinched it, but upon wiggling the tcases for about 20 minutes, I finally got it separated from the tranny and it looks like a piece from the transmission came along for the ride. It almost looks like a sleeve that the input shaft slides into with a groove for a snap ring but im not sure.
I will try and post pics tomorrow but Im wondering if this is the death of my transmission or can I slide it back in, grind my input shaft on the tcase side so it slides in nice and smooth and call it good?
Ok here are some pictures I snapped. Sorry for poor quality but its the best I got.
Couldnt get a shot of inside the tranny.
So thats the sleeve I was talking about, I dont know the technical name for the part. So obviously the splines match up but Im thinking that the are too long on the transfer case side? Also the thing has a death grip on the splines, I cant budge it off my transfer case.
Any insight would be appreciated.
Last edited by OverEazy85; 04-03-2017 at 09:38 AM.
That is the spline coupler out of your transmission. You can see you also pulled the output seal out of the transmission..You didn't have the input shaft of the T/C aligned properly.
what transmission?
are you sure you did not try to force a 21 spline input into a 23 spline transmission? R151 or the original L50/L52 5 speed..
just remembered this little fact about some transfercases out of 79-80's that had an L43 transmission (side shifting 4 speed)
some have to have part of the input shaft ground off (see pic on right)
forcing it will cause the same issue you have going on
I was thinking about the fact that maybe I didnt have the right spline counts but when I went to install it slid in easy, only resistance I got was near the end of tightening it down on the transmission. Looking at those pictures, the transfer case I used for the donor does have the stepped bit on the spline shaft, so there is a possibility that I have the spline count off.
If that is the case, can I get a spline coupler that adapts to a 21 spline? or should I just bite the bullet and swap the cases around and use the reduction box that originally came off the transmission? thinking that the coupler is probably toast now if I forced it. Or could I grind the step off so it fits into the coupler if the spline count is right?
Last edited by OverEazy85; 04-03-2017 at 11:39 AM.
if it is the L series than it should be 21 spline
here is the pic I was originally looking for that shows where you would need to grind the 79-80 shaft
if you shafts look like either of these two you should be fine
Thanks drop! I got it all figured out and ground down yesterday! Dual cases with Marlin adapter, raddesigns triple stick set up and trail gear dual case cross member all in! Just need to shorten and lengthen drive shafts and she'll be ready to sit in my drive way for a bit longer.. Hahah
04-01-2017, 06:25 PM
