1G AWD center shaft stuck in transmission

[markmakeitso]

Hello,
The center diff in my 1G let go, currently trying to take it out and running into some troubles. I have the end cover, VC and intermediate case cover off already. The center shaft (that connects to the transfer case) won't slip out of the engine side of the transmission. Yes, the check ball is removed, should slide out with nothing more than a mallet tap. The pinion gears, pinion shaft, passenger's side gear, and center diff case cover (8 bolts) are all removed already. The remaining parts (driver's side gear and differential case) should also slip out the other side, but that's a no go also.

If my understanding of the diagrams is correct the front output shaft allows the center shaft to pass through the center, and splines into the side gear that sits at the bottom of the differential case. Is a jacked up output shaft possibly causing the troubles, i.e. not allowing either part to slip off in opposite directions? The center shaft spins freely and has about 3/4" slip, when it hits up it feels like a tapered fit locking in, with a small amount of force increasing the friction required to turn.

Tried a 3 jaw puller from the 8 bolt case cover against the center shaft, figuring one or the other should let go, but even an air impact to 140 psi didn't knock either loose. Running out of ideas here, anyone have a solution?

[twicks69]

Take off the car and sledge hammer it out. The output shaft and center diff pinion gearset are junk either way. If you have an air hammer with a point tool, go put some action on it.

I believe I answered this question on Tuners as well. It is straight-forward.

[lilredeclipse]

I normally grab the 5lb sledge and pound them out if they are that bad. Just don't hit anything else.