have few questions about installation of passenger side Output Shaft for 03 non-acd Transfercase.

Once installed is it normal if you no longer can rotate neither Driver side nor Passenger side Output shafts on 03 non-acd TC with your hand?? With Driver side shaft only installed, I can easily rotate the output shaft.

When I install the passenger output shaft with my fingers, I can hear the pin expending, and I can feel the teeth from the output shaft locking gently with those of transfer case. At that point I can still rotate the Driver Side Output shaft, and as a result the Passenger Output shaft is rotating as well. However since the shaft is not fully inserted, I have to hammer it in so the teeth lock together. Once I do that I can no longer rotate the shafts.

I spoke with Shep, and according to him the groove on the part of the shaft that attaches to CV shaft, has to stick out 1" beyond the shell of the TC where the Oil Seal attaches.

When installed with fingers, and rotating, the groove is about 1.25" outside. For it to be within 1" I have to hammer it in, and I can no longer spin the shafts.

Is this normal ?

 

ok . I thought this through and I think I know what is causing my problem. Below are 2 pictues. What I think is happening, once the teeth on the shaft and TC lock, and shaft is still not fully inserted, everything works and spins Ok.

However since it is still not fully inserted, the further you push it in, the area marked in red on the Output Shaft picture below, creates friction with the area pointed by arrows in the picture of the TC.

This explains once I gently tap the Output Shaft deeper, I can no longer spin the CV shaft on the driver side. The passenger side Output Shaft locks teeth with TC, and the friction of the parts highlighted below in the pictures, locks up the gears.

Im just wondering if this is normal case with rebuilt TC. Probably once you run the car, the area will ware out just enough to create enough clearance.

What do you guys think ?

I just ordered new Output shafts, just incase. Maybe it would be a good idea to resurface the old one.

 

Im bringing this back to ask a question since i found pictures.

What is that rubber seal on the last picture? Mine has a small tear where i believe I did it removing the shaft.