Busted Output Clutch Shaft Dana18

Tore apart my transfer case a while back and finally using a Novak kit to do a full rebuild. Didn't pay attention to it during disassembly, but it appears my output clutch shaft broke leaving the broken portion in the rear output shaft?

For reference, I essentially have the item in this ebay ad, but the smooth side is sheared off. NOS Dana Model 18 Transfer Case Output Clutch Shaft for Jeep Willys for sale online | eBay

KaiserWillys seems to only have this for 41-66: Dana 18 Transfer Case

For a 71 v6, is there a better alternative to ebay?


Second portion of this... what are my odds of getting the busted piece out of the rear output shaft? Any recommendations on it? Drill, tap, then try to pull that way?

Many thanks in advance.

 

I would call Kaiser willys and ask what the difference is for your 71. The bushing needs replaced so maybe weld a nut to the stub if flush then use a bolt to pull it out.

 

There are two different front and output shafts for the Dana/Spicer 18 transfer case. The earlier version shown in the second link line drawing is the earlier version. It has a larger diameter and super fine thread pitch. I measured it years ago but don’t remember what it was. Non-standard. The nut and washer were different as well. The nut was castellated and used a cotter pin to make sure it didn’t loosen up.
The later version used a smaller diameter fine thread that was still a bit more coarse than the early version. These used either a pinch style lock nut or a Marsden style lock nut. The shafts themselves interchange but the nut, washer, etc. on the early units are exclusive to the shaft. Yokes and companion flanges will interchange.
My concern with the pilot being stuck in the rear output shaft is WHY did it happen. In my experience usually because the pilot from the front output seized in the rear output and that’s why it broke/sheared.
Personally I’d replace both with good used unit (with good bushing in the rear output) and update. The later shafts used the same washers and nuts as Dana/Spicer 20’s and 300’s so are very common and readily available.

 

This would be much preferable to a reproduction part of questionable quality.

 

Check with Novak Conversions. They likely have the pieces in stock.

Parts for the Dana Model 18 Transfer Case

Mike

 

Richard at 503-557-8911 most likely has all the parts you need. Herm probably does too.