I have my 241 dld out in my neighbors garage, with its cracked case and the replacement with the EXACT part #, out of a auto also, has an input shaft that is 3/4" longer!!

What are my options; how hard are these input shafts to swap? I took the seal off and looked at it, but it looks like I would have to split the case to swap them?
I am siliconeing my old case as we speak so my neighbor can have his garage back, but it is still on the bench.

got sawzall

 

Yup, split the case and keep track of everything. It's pretty easy. Did my 271 when I bought one for an auto to put behind my 6 spd.

 

The assembly numbers are the same?

There is a .840" exposed input shaft and a 1.55" exposed input shaft and the difference is .71".

 

ok- that would explain alot! I looked at some pics, and you do have to spit the case to change out the input shaft, right? How hard is this? Thanks, bruce

 

I think I have to give up until the AM- neighbor is an early riser, so I don't want to wake him up tonight... I think I will just give the silicone some time to cure, and run the old case, unless I can find out how hard they re to swap. This thing has me frazzled...

 

Checkmate- I just noticed your post Any special tools needed, or is it an OK job? I really would like to do this the right way; it's a pretty long crack in my original case, so it would always bug me...

I should have done my own work the first time- then I could blame myself for not getting the front driveshaft bolts tight

 

Its' not very hard to change the input shafts; a friend & I changed mine out a few years ago in my '96 gasser. Neither of us had ever taken a transfer case apart before but if I remember right its' just snap rings & smaller parts & remembering where they go.
Not too much for special tools; I think snap ring pliers were about the worst of it?
This is what you have to remove (in a 231D anyways) & change out.

 

YEP!! That's the animal- I weakened at the last moment tho, and took them both to a tranny shop and let them take my $200 to give me it back all in one shiny clean working unit I don't get it back till sometime tommorow, but I have been screwing things up lately, and decided to pass on this one...

 

thanks for everyone's help on this- like always, AMAZING place/people...

 

200 insurance if something goes wrong. Some time we work are our source of income so we don't always have to work on our toys. I think that is reasonable.

 

It`s easy. I can send you pics if you send me your email. Or I could post them.

 

email rec409@alaska.net

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