Dana 18 part question

I am rebuilding a transfer case that I got that is disassembled. It is the big hole 1 1/4" shaft type.
My question is about the clutch shaft gear. Part # 49 in the FSM. I have two of these gears and neither one fits on the Output Shaft, part # 55. The splines are cut deeper on the shaft than the splines on the gear.
Do I have the wrong shaft, or wrong gear?
Thanks and happy T-day

 

Correct parts #9 and 17. The parts were aquired loose from boxes that contained enough parts to build 2 or 3 cases. The second gear I picked up on good old ebay.
I also picked up ten or more spare gears. From the above exploded diagram, parts 13,14,18 & 23. (all dif gear counts and part numbers)
I guess my question is did the earliest gears (part 17) have same spline count, but different depth of splines, than the later big hole case? Or do I have the input shaft (part 9) from a model 20 transfer case?

 

all 18s use the same parts #9 and #17
the 18 uses a long rear shaft and short front shaft whereas the 20s have 2 shafts which are about the same in appearance (they aren't the same)
the 20 does not use #17 at all
fwiw

 

ok, heres a pic. going from left to right: output clutch shaft, clutch shaft gear, input shaft.
I have two of the clutch shaft gears. Diameter is correct, spline count is correct, but the spline depth is deeper on the shaft, than on the clutch shaft gear.
I guess I am confused about which part is incorrect, and how tight they are supposed to be. The gear will start on the shaft, but is very tight. Any ideas?

 

mis-machined, mis-cut splines, or different supplier?
from 1941 to 1971, those parts are the same on all D18s

 

I would say that you most likely have some burrs somewhere not allowing them to mesh properly. I've interchanged those parts for years and rarely had a problem, and then only when a part was damaged (had burrs causing a hang up). You want to also make sure the front output shaft pilot is not real loose where it goes into the bushing in the rear output shaft. If so, try and get one that fits tighter or replace the bushing. There should be some clearance, but should not be sloppy. Nickmil.

 

Thanks for the input everyone.
Howard Eisenhauer; the picture from the link you posted is exactly what I was talking about. If you look at the excellent photo of the two gears, the splines are very different. If you look at the inner splines, one is cut deeper than the other one and has a very slight taper.
The two gears I have are like the one with the square cut, shallow splines. Hence it no worky.
I also wasnt aware that AA made a different kind of Intermediate shaft. Great info everyone, thanks.

 

The gear on the left has the proper markings stamped on the face. The one on the right I suspect is some 3rd world repro part. Phillipines? China? India? Just my .02