Transfer case input shaft groove -- speedi-sleeve?

Recently pulled my transfer case and transmission (M/T, 3.4, J-shift) to fix a leak between the t-case and transmission extension housing.

I noticed that the T-case input shaft was noticeably grooved in the spot where it rides along the output shaft seal in the transmission extension. (part pictured)



I resealed it all but I'm worried that it's going to leak again given how deep the groove was.

Anyone else experienced this? A few options I'm considering if it leaks again:

1. Replace the extension output seal, but don't drive it as deep into the bore in hopes of riding on a different part of the t-case input shaft.

2. Measure and find a Speedi Sleeve (anyone tried this) for the grooved t-case input shaft.

3. The actual t-case input shaft part (36201-35040) is available new from Toyota, not sure how difficult is to replace the old one (guessing it's difficult)

4. Source a good used t-case.

5. Find a rebuilt case (so far all I can find are rebuild gear-driven cases, not the chain-driven ones on the 3.4).

Any thoughts?

 

I have a spare j-shift input from my Ecocrawler swap. It's yours if you want to figure out shipping. I'll grab a photo.

You could get a new one from Amayama for ~$170, But Partsouq says they are not available... so...




Wear looks very minor on this one. I can't really feel it with my fingernail.

 

Awesome, I'll hit you up. Any idea how difficult it is to replace? Don't have a problem with splitting the case, just want to make sure I don't need a special array of pullers or measuring tools to get the new shaft back in there.

Curious if anyone else is seeing this. My truck has a ton of miles on it (400k), but other than that the trans/t-case have been generally well-maintained.

 

Check out the first few steps in this manual. https://cdn.shopify.com/s/files/1/0509/2261/9043/files/Eco_Crawler_Installation_Manual_-_VF2_R07.pdf

looks like it should be easy. I don't remember it being particularly challenging, but I've done this sort of thing a few times.

 

I have used those sleeves lots of times. The problem I have is that the installation tool is OK for about 5% of the jobs. I usually have to make an installer as the one in the kit isnt deep enough. I am usually installing these sleevs on axle stubs or input shafts that are longer than the depth of the installer. I learned many years ago that if I am going to buy one, I better buy 2 or 3 just in case... they never seem to install "just right" the first time.

 

Just an update on this for anyone wondering -- replacing the input shaft with a better one from ZColorado seems to be working so far. (Thanks!)

The one he had appeared to be one from an auto transmission truck (the t-case input shafts actually differ based on whether they came with an MT or AT) but the length and position of the splines appeared to be the same so I'm giving it a shot. So far, so good.

Taking apart the t-case and replacing the shaft was easier than I anticipated, just some retaining rings here and there to remove and a couple of delicate oil seals to transfer. I put the case into 4-hi before I took it apart and that seemed to keep the gear stack together nicely so I didn't have much to reassemble. Resealed with FIPG.

Assembling the t-case back onto the end of the transmission while it's still in the car is tricky -- it's pretty easy to bugger up the transmission output seal with the t-case input shaft if you don't line it up pretty straight before inserting it.

I ended up buying 6 pieces of threaded rod from McMaster (M8x1.25 -- I got studs 200mm long but I would go a bit shorter next time). I put 3 rods into the transfer case, 3 into the transmission, and use the threaded rod as a guide to line up the transfer case onto the transmission (I basically bench-pressed it off of my chest and onto the threaded rods, then slid it into place). Then I removed the rods one by one and replaced with bolts.

Seems like wear on this output shaft is a pretty rare occurrence based on my forum searches -- but my rig does have 400k+ miles on it.