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Busted Output Clutch Shaft Dana18

Discussion in 'Early CJ5 and CJ6 Tech' started by TerdFurgeson, Jan 21, 2020.

  1. Jan 21, 2020
    TerdFurgeson

    TerdFurgeson New Member

    San Antone
    Joined:
    Nov 3, 2017
    Messages:
    12
    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.
     
  2. Jan 21, 2020
    Jw60

    Jw60 Recovering Jeepaholic

    Sedalia MO.
    Joined:
    Oct 5, 2018
    Messages:
    405
    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.
     
  3. Jan 21, 2020
    nickmil

    nickmil In mothballs.

    Happy Valley, OR
    Joined:
    Sep 23, 2002
    Messages:
    11,525
    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.
     
    Vanguard likes this.
  4. Jan 21, 2020
    colojeepguy

    colojeepguy Colorado Springs 2019 Sponsor

    At the foot of...
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    Apr 4, 2010
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    4,492
    This would be much preferable to a reproduction part of questionable quality.
     
  5. Jan 21, 2020
    Howard Eisenhauer

    Howard Eisenhauer Super Moderator Staff Member

    Tantallon, Nova...
    Joined:
    Nov 22, 2003
    Messages:
    5,975
    I had the exact same issue, parts supplier sold me the later piece, then they had to send me a nut to fit it.
     
  6. Jan 24, 2020
    BadGoat

    BadGoat How High Can You Climb?

    St Croix, USVI
    Joined:
    Apr 27, 2017
    Messages:
    104
  7. Jan 26, 2020
    nickmil

    nickmil In mothballs.

    Happy Valley, OR
    Joined:
    Sep 23, 2002
    Messages:
    11,525
    Richard at 503-557-8911 most likely has all the parts you need. Herm probably does too.
     

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