I am in process with my LT230 swap and have run into a problem: The case has slide onto the trans splines all the way up to 1/4 inch from being flush, face to face. Now that it is that close it has stopped and will not go on any further. Has anyone ever experienced this?

Sounds like you might have the wrong coupling shaft. There is a long spline shaft that goes with the drilled in put gear.

http://homepage.mac.com/noahlmil/images/tcase4.jpg

Sounds like you might have the wrong coupling shaft. There is a long spline shaft that goes with the drilled in put gear.

http://homepage.mac.com/noahlmil/images/tcase4.jpg

dead right, the longer spline one you need is FTC5090,

That looks like it! I have the spline shaft pictured on the left. Do I have to buy the shaft from a dealer or is their a better source out there that wont charge me an arm and a leg?

Having the wrong shaft is the usual cause for this problem, however, occasionally someone will assemble the transfer case with the input gear in backwards causing similar problems.

I got mine from Atlantic British because I have an account with them. They retail for about $100.

Check to be sure you have the drilled input gear first to make sure of the problem.

Ummm, I had the same problem.

Correct spud shaft, gears installed correctly, conflicting locating dowels were the problem!

Two dowels and one hole do not a mate allow.

Might be worth a simple look.

I already dealt with the dowel issues and I am positive the input gear is installed correctly. I am pretty sure the spud shaft is the culprit. Is it just the length of the groves that is different? I'm sure I could put this on the mill and extend them a bit.

Two dowels and one hole do not a mate allow.


I've done this swap once before, didn't have the dowel issue. I can't remember if these dowels are removable or not. What did you do with your conflicting dowels?

I'm getting ready to swap one into my LWB in about a week. :(

Man, I must've gotten really lucky! I JUST put an LT230(looks to be from an old RR) into my 93 LWB two weeks ago and I didn't know anything about different coupling shafts. Does this apply to certain model years? I just dropped the B/W and put on the LT--no issues...

What did you do with your conflicting dowels?
:(

I grabbed the one that stuck out the most with the vise grips and it wiggled right out! Sometimes even a blind pig finds an acorn :)

Can't take much credit, it was on suggestion of Mr. Roadside :cool2:

Nomar, I'm jealous, no issues!

I've spent the last 4 days (not all day) replacing my heater core because I lowered my gearbox just a little too far. Driveshaft was supposed to arrive monday hmmm... Anyway, dash is almost back together.

Cheers,

Having the wrong shaft is the usual cause for this problem, however, occasionally someone will assemble the transfer case with the input gear in backwards causing similar problems.


Heeeeeyyyyyy!!!!

I have the number you need, I'll call you tomorrow.

I emailed you earlier, but I will second the part about the dowel. I struggled to figure that one out for two days, never noticing them both at the same time.

I'm getting ready to swap one into my LWB in about a week. :(

I'll be waiting for your call.


:flipoff2:

-Jeff

I'm about to put my 1:1 box in.

I finally found the source of an oil leak that has pissed me off since I owned the truck.

The clowns who put in the isuzu engine and gearbox made a shaft by cannabilising the old LT77 shaft. Their new shaft had a weld right where the seal ran, so they simply threw away the input seal.:mad3:

A bit of turning, welding and turning and it might hold oil this time as there is now a place for the seal.

My planned gearbox swap has hit another snag. Isuzu changed splines (both input and output) so I need to get a new adaptor shaft made which can't happen till after new year.

Looks like it's all gotta come back out again. Nothing like putting a gearbox with noisy bearings back into your truck.

I guess I will start calling around tommorrow for the spud shaft.

As for the dowels, I just grabbed the ones I wanted to remove with pliers, twisted and pulled.

Series One - and whom ever else is interested; I have been documenting the swap pretty well on digital camera. I can post it all up by this weekend! Where should it go?

I'll be waiting for your call.

:laughing: True dat.

I guess I will start calling around tommorrow for the spud shaft...Where should it go?

It should go in the back of the transmission between it and the t-case. :laughing: Damn I'm funny. :shaking:

If you need some webspace to post the pics et al, I can provide.

I'm getting ready to swap one into my LWB in about a week. :(

I take it you finally received your shifter (and your wife's cell phone charger)?

I was so excited to tell you the radio show about Larry was on, I forgot to ask:D

Did it have all the bushings? If not, I can send you the remaining ones I've been carrying in my change purse for nearly ten months now.

I take it you finally received your shifter (and your wife's cell phone charger)?

I was so excited to tell you the radio show about Larry was on, I forgot to ask:D

Did it have all the bushings? If not, I can send you the remaining ones I've been carrying in my change purse for nearly ten months now.

...ironically it's sitting unopened in my garage right now.

Spent yesterday cleaning out the garage, cleaning up the bench, moved the truck into the garage and got it up on ramps. Looked at the box, thought about opening it, but didn't. Ran out of time to work on the truck and had to go to two Christmas parties. :flipoff2:

I'll let you know if I need any bushings. I'll start on it tomorrow...maybe tonight.