4wd conversion. Need help please.

So I'm in the middle of my 4wd Convertion but my t case will not close up to my adapter. I believe it is the input shaft on my t case that is not allowing it to mate to the extension housing properly. Is there something I could do about the input shaft. Read some where it was for a manual trans and that's why it won't mate. Can I just replace input.

 

Here is a pic

 

wheres the housing?

 

What kind of engine and transmission did the transfer case come off of? v6 transfer case is top shift and inline 4 transfer case is forward shift and has an extra intermediate housing to allow for the length difference of engines.

 

The tcasr came off a v6 from what I was told. Here I'm my trans

 

test fit the spline of the tc to the tranny?

 

Are you sure that there isn’t a dowel pin in both the transfer case and the transmission? There a couple pins that align the two and there’s a chance you accidentally have it one both halves. I feel like this isn’t making sense as I type it. But the alignment pins are only supposed to be either in the transfer case or in the transmission. When I did my conversion, the transmission had the pin and the transfer case both had the pins. It kept them from completely coming together. There was about a 1/2” gap. Took awhile before I realized what it was.

 

This is exactly what is happening to mine. I have a half inch gap. So where are those pins at ?

 

Along the mating flange where the bolts are. There’s a couple holes with short 3/8” dowel pins that help align the TC to the trans. Just make sure they are only in either the TC or the trans.

 

I believe it is only on the adapter. Right?

 

This is as far as it will go in

 

remove tc and adapter from tranny, try to mount adapter into tc?

 

Right now it looks like its sitting on the shifter rods. Have you tried to put the shifter in 2wd, or another position to see if that helps? Also try turning the rear tcase driveshaft flange to see if wiggling will help seat further.

Also like previously stated, try test fitting the tcase directly to the trans without the adapter housing.

 

It still will not seat properly. Could it be that my t case came out of a manual trans and that it's diffrent?d if so do I need a new one or can I swap something out

 

Ok so tcase adapter fits to trans. Check.
Tcase fits to the tcase adapter. Check.

Try just sliding on the tcase without the adapter to verify it will engage to the output splines from the transmission. If it wont, itll confirm your tcase has the wrong spline count.

 

It's spines In no problem. Buts the output shaft hits the back of the Input shaft. It will not go in any further.

 

You used a t-case off a manual trams? That sounds like why it isn't fitting. Output/input shafts may be different lengths.

Someone correct me if I'm wrong.

 

Yep, I agree now. Since the splines matching up but the length is still too much then its a missed match manual/auto trans combo.

 

As far as I know you can't use a v6 transfer case with a I4 transmission or a manual tranny transfer case with an automatic tranny transfer case.