I broke a rear output shaft a while back and just got around to replacing it with a Bobby Long chromoly output. I put it all together, installed it and it appears to be stuck in in 4wd. I have a twin stick and it seems to shift okay, but both drive shafts turn in 2wd. I took it for a drive around the block. Both drive shafts are still turning, but now it wont shift into 4wd.
I took the back two cases off and couldn't find anything wrong so I thought maybe I needed to grease things better on the output. Greased it all up and put it back together. Shifts fine and works fine until I tighten the rear output flange. Both drive shafts start turning again in 2wd. So the obvious answer is a spacing problem on the output not letting the "clutch hub" spin freely.
I have a factory FSM and I don't see any options for spacer thicknesses or anything like that.

So, :confused::confused:

Call Bobby's techline, He answers any day of the week when he is home.

Only thing I can think of is you missed something on assembly possibly put something back on backwards. Other than that it'd be a manufacturing thing.

Mine went in fine, only issue I had was it seemed to have a bit of a bur on the output flange coupler teeth, which I cleaned up with a soft wire wheel.

Yo Pat, unlock your hubs...:homer: If you find a fix we are going to TM this coming weekend for some seat time, wanna go??

Thats funny a buddy of mine put his bobby long shaft in his toy tcase and the samething happened.So we tore it down again, took a mike and started to messure the differences between the stock shaft and the long one.We found that the Bobby long shaft is short by 10 thousands where the 2 gears meet for 2 and 4 wheel drive under the shifter colar .When you tighten the output flange down it pushes the two together.He ended up turning the spacer(the one by the snap ring end) down to let the gears slide forward 10 thousands and it fixed the problem.He is going to give Bobby a call tomarrow.

I talked to Bobby today. He knew exactly what happened and is sending out a new output tomorrow.

Yo Pat, unlock your hubs...:homer: If you find a fix we are going to TM this coming weekend for some seat time, wanna go??

Everybody gots jokes :flipoff2::flipoff2:

I can't go next weekend Sam. I wish I could, but I'm going to be at a 24hr mountain bike race. My wife is racing and I'm the official beer drinker. Hope I don't fall in the fire this year...

Everybody gots jokes :flipoff2::flipoff2:

I can't go next weekend Sam. I wish I could, but I'm going to be at a 24hr mountain bike race. My wife is racing and I'm the official beer drinker. Hope I don't fall in the fire this year...

Man you can drink alot of beer in 24 hours:smokin:

Beer, Thats for your cereal in the morning, ask 80 proof.

Beer, Thats for your cereal in the morning, ask 80 proof.

Shoot, I wouldn't even waste a crappy bowl of cereal by pooring beer on it.:D