Tcase history: Evo 9 ACD tcase that has 47k miles, no unusual sounds, metal shavings or any trouble. Removed to install non ACD tcase.

Problem: New owner says that the tcase shaft (passenger side axle) pops out pushing the axle off and spilling fluid when the car gets put into motion. However the the shaft when installed does lock unless you pull really hard by hand.

Do you guys have any suggestions on what it can be? Doesnt make sense to me unless its not being installed correctly from the first place. The original input shafts (driver and passenger side) i re-used on my current setup without any problems. I used a slide hammer to pull them out and the splines where in perfect condition.

Thanks,

 

there are some c-clips on the axle shafts, maybe one is not installed (probably on the passenger side) and its allowing the axle to move about.

 

Id like to agree with the above comment. From what i understand that axles arent suppose to be able to come out with a hard tug of the hand. And i actually am in the process of removing my transfer case and when i went to pull the axles they were suprisingly more difficult to pop out than i thought. So my guess would also be maybe a damaged c-clip? Best of luck. Hopefully it works out well

 

They told me that they bought new input shafts w/ c clips from the dealer because their old broken ring/pinion tcase also had something damaged that damaged the original input shaft splines.

Also with the damaged internal tcase is able to hold the new shaft in? Which doesnt make sense, if the old tcase was damaged enough to destroy the splines on the input shaft, how would you be able to install a new shaft in it correctly?

This also makes me wonder, if you dont install the shaft correctly the first time around (dont punch it in all the way), and you drive your car, wouldnt it hurt the tcase / shaft splines ?

 

Well looks like they were "unable to resolve" the popping out issue.

I'm going to offer them a refund, but under the following condition since I know that it was in 100% working condition before sending to them, and also to make sure they didnt swap any parts or damage due to install error.

1. They send it to Shep Trans for inspection.
2. Shep inspects tcase:

if:
a. Its been opened before or parts have been swapped I will not refund the money they pay shep.
b. Its been damaged due to install error, I will not refund the money they pay for shep.
c. No swapped parts, damage exists and not caused by install error, I will refund the money minus the shipping cost agreement. (700+60 shipping) so they will get back 700 dollars. Also I'll follow through with sheptrans.

I got to protect myself as well and something definitely does not add up here. Do you guys think I am out of the line for this option?

 

Pull the axle out and snap a pic of the shaft and the bore of the t-case. If that axle is popping out thats a serious issue.

 

I'll ask him to see if he can snap pictures. For the record, tcase looked good when I had it also the input shaft splines were also great and I reused it on my current tcase without any issues.

 

is driveshaft thats poping out OE mitsu or aftermarket? Ive seen aftermarket shafts being assemble incorrectly poping out. Real PITA.

 

this new oem from Mitsubishi dealer..

 

Interesting....did new owner installed himself?