Propshaft stuck in gearbox

[Charlesb]

I have been trying to remove the drive shaft to replace the oil seal. it will slide on the splines, but comes to a hard stop, and will not come off. I've had a good look at the diagrams, and cannot see anything obvious. the only thing I can think of is that there is a very slight play in the output shaft, and maybe a lip has formed on the bush? That would probably be the cause of the oil seal failure.
Has anyone any ideas, or does it look like I will have to take the gearbox out, and pull the end case off.
Also, how difficult is the output shaft bush to replace?
Regards

Charles

[dan_2k_uk]

I wouldn't have thought anything would easily stip that from coming off.

Presume you've pulled it pretty damn hard?

[Charlesb]

I can slide it quite a way, so using the mass of the propshaft, I'm giving it a good wack. I've tried a lever as well but not easy to get a good pull. It feels as if its coming up against something really hard. It doesn't jam at all, which I would expect if it was a burr or corrosion etc.

[dan_2k_uk]

Yeah that's odd. In itself the whole thing is basically a slide hammer so you would have thought if there was a little lip or burr it would get jammed on it like you say.

There really is nothing there for it to get stuck on though.

[Charlesb]

Yes, I can slide it about 25mm. the odd thing is that, even slid right out and pulling hard, it still spins free with no rubbing. So I assume it must be something on the spline rather than the casing or bush.

[dan_2k_uk]

I've got a spare shaft here so just checked it for you. The splines run all the way to the back of the female part on this shaft so don't see how the male part could twist or mushroom to lock it in there. Maybe some differences between shafts as there seem to be with Suzuki.

[dan_2k_uk]

Can't be the whole shaft moving in the gearbox either as with that much play it would have destroyed itself.

[Charlesb]

I thought about the shaft moving, but the gearbox works fine. Looking at the cross section drawing,I can't see anything to stop it. The splines must be fine, as it slides smoothly. Even if I remove the gearbox, I still can't take the end case off until the propshaft is removed.
I can't be the only person to have had this problem!

[dan_2k_uk]

I googled what I could in English and American wording and couldn't find anyone else reporting the same issue on any forums.

[Charlesb]

I think I may know what the problem is. Looking at the cross section drawing, if the bush had seized on the propshaft, and was spinning in the end casing, then it would give the symptoms I have. It would slide in and out, but bump against the oil seal. It should pull out with the oil seal with enough force. The end casing should also come off with the shaft and bush. It would probably mean the end case was damaged, although I have very little side play, so I could be lucky.
Any thoughts?