So I'm in the process of dropping my trans and transfer case. The passenger side axle sure needed alot more oomph to get it out. And when it did come out, it came out with the output shaft. And of course, being so long, I cannot get it out, because the last boot is hitting the oil pump housing. Has anyone had this happen? I'm hoping the splines arent twisted together etc. Has anyone had this happen before? Trying to figure out where to go from here.

 

this happens sometimes, nothing to worry about. you can seperate them with a hammer and chisel if you cant pull the whole thing out

 

I got them separated no problem. What a pain to get out though. I bent the last metal part of the axel (one between the green part and transfer case) just a little bit. I sort of banged it back into shape, but wondered how this would affect anything? I know the rubber seal goes into this part, but wondered if I need to get a new axle now???

 

It should be fine, I think it is a shield for the rubber seal to stop it being damaged. If you get it close to the original shape it will be ok.

 

Yeah bud, I damaged the dust shield too. I didnt even really bend it back because it wasn't too bad. I have no problems so far!

 

my passenger axle is stuck to my transfer case too haha I just left it attached
I think there is a snap ring in there just make sure thats not broken and it should be ok

 

To OP or anyone who has had this problem: How did you get the output shaft separated from the axle once both are out of the car and away from the transmission?