Sheldons was designed to fit.the.long splined gear as well. As i have said earlier
Boof
I prefer to post here now for kit issues.
Regarding your picture. To me it looks like twist in the reduced diameter area, if that is what you are referring, but I am no expert.
I would expect the Outcast unit to shear, if its going to shear, in basically the same spot. The Outcast was designed to fit the long spline input gear, and only about 20mm of the Outcast male goes unmatched by the input gear female.
As 85county. lotza and others are suggesting, casing alignment or rigidity may be the culprit. Just for clarity you say your case was rewelded are you talking before your shaft broke or after?
Sheldons was designed to fit.the.long splined gear as well. As i have said earlier
I should have gone into more detail.
The Sheldon shaft should fit into both. Measurements Vern gave me indicate the Sheldon splines are much further toward the pto cover end than the Outcast - see link.
I don't have a Sheldon shaft, so I can only judge by the best info available to me, and it would seem to me that maybe the Sheldon shaft was positioned to engage with the short spline set in the old input gear - even though it can fit into the later long splin input gear it cannot avail itself of all the long input gear spline.
If Vern sees differently, having the Sheldon shaft at hand then so be it, I must not have all the required info. Given we seem to have different spline counts on gearbox output shafts, then maybe I need the length of the output shaft on Verns MSA, and the distance from the back of the MSA to the coupling face of the MSA drive flange.
Correction to the drawing, after pulling the oil seal to improve measurement, the 30mm noted as being the distance from the t/c case to meeting the first taper race is more like 22mm.
This places the taper race further left, closer to the rise to the oil seal landing. The Outcast shaft at that point is tapered to go into the input gear whereas the Sheldon has a sharp shoulder at roughly the same point. As said above, if I'm missing an important measurement then moot point.
Otherwise, just a thought, is there any sign of the Sheldon/Boof ed shafts rubbing/indenting/fretting the adaptor side of the input gear or the shaft itself? Is there is any chance that the shoulder pushed the input gear toward the pto, thus removing any 'end float', or 85county would that scenario be a proper case of unwanted 'preload'and stressing the shaft and case (and bearings)? The error might be only a few mm and not enough to be noticed when attaching the t/c to the adaptor, particularly given you're dealing with the 1.003.
If it were the 1.22 you might notice the problem as the last thing to do is insert the input gear.
http://www.aulro.com/afvb/attachment...t-imgp3250.jpg
Any further progress Damien?
Steve
1985 County - Isuzu 4bd1 with HX30W turbo, LT95, 255/85-16 KM2's
1988 120 with rust and potential
1999 300tdi 130 single cab - "stock as bro"
2003 D2a Td5 - the boss's daily drive
Nah been to busy with work etc.. also waiting to see if lokka can cnc the spacer plates i need. Once i have them i can do something
Transcase off, stuck the mxa flange in, will fit into the lt230 perfectly, so just need to measure up and make a shaft.
Measured up my adapter housing, it .16mm off centre to the msa output shaft, all runs true though.
Just a 4mm thick disc the same dimensions as the gearbox drive flange.
Just waiting on a reply from lokka first, would prefer to keep it inaulrohouse, if he can't do it i'll let you know
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