Thread: transfer case rebush intermediate shaft question.

I had it in mind to ask this for ages now, but have continually forgot to remember to ask:

Anyhow, the commonly accepted method to resleeve a transfer case/intermediate shaft problem is to mill the transfer case and insert a sleeve to suit a standard sized intermediate shaft.

Seems like a lot of work, especially the milling of/resleeving the transfer case part.

Wouldn't it have made more sense to insert a slightly smaller bush straight into the regular transfer case and then whack the intermediate shaft onto a lathe and reduce the size of the shaft end to fit the now smaller new bush?

eg. Ashcrofts sell the bush and intermediate shaft parts to do this. Bush is relatively cheap, intermediate shaft not horrendously expensive .. but the transfer case milling process seems to be a fairly expensive episode.
Bush would still cost the same money, so would a new slightly undersized intermediate shaft(it has to be machined to whatever size anyhow) .. but then you wouldn't need the expense of resleeving the transfer case, just press in a new hardened bush.

I assume that reducing the diameter of the intermediate shaft head may have issues, maybe.
Otherwise, it makes no sense to me to do it the way it's done currently.

Just curious on any experts thoughts as to why it was chosen as the common way to do it.

Here in brisbane you can get an exchange bushed case for $195, from MR Auto.
I think that is reasonable.