R380 output shaft. Anyone seen this before?

[Svengali0]

This is output shaft suffix L gearbox.

https://www.aulro.com/afvb/images/imported/2014/10/1038.jpg

With input gear. Notice the gap at the end? This ends up being a problem when fitting the LT230 box. Input gear is not seating correctly.

https://www.aulro.com/afvb/images/imported/2014/10/1039.jpg


This shaft on the suffix J box just removed from the vehicle. Splines don't terminate and allow the input gear to butt up against the collar.

https://www.aulro.com/afvb/images/imported/2014/10/1040.jpg

Input gear fitting neatly on the shaft- no issues.

https://www.aulro.com/afvb/images/imported/2014/10/1041.jpg

Has anyone seen this before?

Ideas/Solutions?

[bee utey]

Faced with that scenario I'd happily put the input gear into my small lathe and trim the internal spline with a tungsten carbide tipped boring bit. You obviously only need to take off enough to match the curve at the inner end of the shaft spline. It wouldn't significantly weaken the drive.

[justinc]

For starters the input gear should be the other way around, and if there is still a problem then you will have to bore the inner splines of the input gear.

Jc

[Ancient Mariner]

The gear is arse apeak X2

[Ian Ashcroft]

X3 It's so embarrassing isn't it??? Ian ashcroft

[isuzurover]

x4

If you had the t-case bolted up you would realise the error of your ways...

[Blknight.aus]

X5.

[Svengali0]

ok kill me now....
But in defence, when the case was bolted up I did 'try it both ways' and the gear seemed unwilling to home in correctly.
I should um, stick to my day job then shall I...;)

[PAT303]

You are going to replace the bearing aren't you?.Remember,it's better to ask a dumb question than make a dumb mistake,good luck with it. Pat

[Jode]

X3 It's so embarrassing isn't it??? Ian ashcroft
Aw, heck, Ian, very few of us are anywhere near as experienced with LR gearboxes as you. Hand on my heart, I could very well have done the same thing in the heat of the moment. Let's all just take a deep breath....

[Svengali0]

You are going to replace the bearing aren't you?.Remember,it's better to ask a dumb question than make a dumb mistake,good luck with it. Pat

The input gear pictured comes from the removed (old) transfer- just placed for reference purposes. The input gear that will be used is that which came with newer transfer- I was thinking of replacing those bearings but lack the tools to measure the preload not to mention ready access to the shims.
I've pulled quite a few of these transfer input gears and lower access casing plate off in the past (checking each vehicle I buy) so really there's no excuse for putting the gear the wrong way around and then asking for help and advice.
In my trade we call this 'perseveration'. In other settings- repeating the same operation hoping for a different outcome is termed some rather derogatory names.
I guess at the end of the day- I did get an answer for which I am grateful. Yes it is embarrassing and that does sting a bit.
Notwithstanding- you make an excellent point Pat so thanks for the reminder.