C4 won't bolt up

[akaFrankCastle]

I have an obstruction of some sort between the transfer, intermediate, and C4. If I bolt the INT housing to the C4, I have a gap at the transfer. If I bolt the housing to the transfer, the gap is on the C4 side. Gap width is about 1/8-1/16" in width. I've wiggled it, jiggled it, shook it and cursed at it.

I suspect the issue is the intermediate shaft or output shaft as the transfer case binds when I apply slight pressure to the bolts during tightening.

Thoughts?

[mickphatmac]

I think you nailed it on the head. I bet if you grind it down the fat end of the shaft, you will solve your problem.

I had purchased an automatic for an intermediate housing and turned out the shaft was cut off and reused in the automatic from a previous standard transmission. The back half ( in relation to the front and the back of the Bronco) that goes into the Dana 20 looked exactly the same but it was the front end that slips over the Trans shaft that they needed to cut off and grind down.
Auto vs Manual...

[ZOSO]

Yup just what he said^^^^ You need an intermediate shaft for an auto. Even if you cut the manual down to the correct length it's not splined deep enough(been there tried that).

[Digger]

Wow, that's poor engineering

[Viperwolf1]

What they said. Manual spud shaft. Some of the manual spuds are deep enough to cut and use. Splines are short on the manual spuds but some also have shallow holes. It must be deep enough to accept the length of the C4 output shaft.

Bronco 008.jpg

Bronco 309.jpg

Bronco%20307.jpg

Bronco%20313.jpg

[mickphatmac]

Does the "Inner spline to end shaft length" have to be 2" or is 1.5" ok?

[Gunnibronco]

Advance Adapters told me that you want as much spline engagement length as the cross section width of the shaft. Even a little less is ok.

[Viperwolf1]

Does the "Inner spline to end shaft length" have to be 2" or is 1.5" ok?

1.5" is what the auto spud measures. With a cut manual spud it'll be closer to 1".

[akaFrankCastle]

So, I've confirmed it is definitely a manual spud shaft.

Retainer to spud shaft end is at around 2.5"




Threads inside the spud are about 1.5", as predicted.



I'm going to stop by Don's this weekend and see if he has any auto spuds. If not, I'll be whipping out the grinder and sacrifice a manual spud to make this thing move a little on its own.