Topic: 2nd case broke?

[jakeo]

I just installed a dual case adapter in my truck. I had a buddy help that has done 3 or 4 before mine so i am pretty sure that it was done correctly. I went to drive my truck last night after it was all reassembled and it wouldnt move. I thought that the rear case was stuck in neutral and was bound up. I pulled the shifter and manually shifted it into 4 lo and it still wouldnt move. So today i pulled the case and it outputs turned fine when I turned the input shaft by hand. I cut the drivers side shift rail becuase that was origionally forgotten and reinstalled it tonight. Got in my truck to try and drive and nothing again. With the shifters out i can see that the front case is spinning and the rear is not unless it is put into the neutral position. Anyone have any suggestions? I am looking to get out this weekend and dont really want to buy a new case.
Thanks for your input.

Jake

[RRMike]

Is the front case in neutral??  Sounds like a stupid question but if the output on the front case isn't spinning it's in neutral of something is definately not put together right.

[jakeo [OP]]

Im pretty sure that the case isnt in neutral. I shifted if from high to neutral to low and felt the output all three times. The time it was in high it was spinning pretty fast, neutral i could stop it with my hand and low it was spinning slower. Anyone else have any ideas?

[79coyotefrg]

when you cut the shift rail  was it in 4Hi?? cause it should be

[79coyotefrg]

if the d side rail isnt cut  it wont go into 4hi and it has to go into 4 hi befor you can go to 2wd

[jakeo [OP]]

When I cut the shift rail it was in 2 hi which means the drivers side rail is in the same position as 4 hi.

[Chad_Romine]

What did the donar case come out of? sounds like install error to me.

[854RUN]

Sounds like the output shaft in the 2nd case is broke. Pull the 2nd case and put in 2wheel then spin it by hand and go from there. If the rear flange spins than its not the output shaft. Then it could be the rails. At least you would know that it is not something like the output shaft.

[jakeo [OP]]

I figured out the problem. I pulled the rear case today and counted the splines on the output of the crawler. Yep 23 of them. My case is only 21. I am pretty dang sure I ordered a 21 spline for my 88 4 runner. I emailed them and tried calling them but got no one so hopefully they can fix the situation somehow before the weekend becasue we are supposed to go wheeling.

Jake