Look what I found today [PICS]

[chevychic]

I was finally able to get my truck pulled (and pushed) around to the car port so I could start looking at things to determine which part of it was broke.

I started at the governor, pulled it since it was the simplest thing to do. It was in perfect shape.
Next stop was the transfer case. At a tranny mechanics request, I drained it into a pan with a magnet in it to check for any metal. Nothing, the fluid that drained out was clean.
Then I moved to the tranny.

I drained it and here's what I found:



Looks like all the teeth to my spline have been shaved off. From what I can tell, they went directly into the pan and don't appear to have gotten into the tranny gears. The fluid is also in good shape and doesn't smell burnt.

There's a guy locally who can build any driveline part you want. I'm going to find out how much he'll charge to build me a new, stronger spline. I'm also going to check into using the spline out of my old 700R4 I have sitting here, but who knows how much abuse it's had.

Hopefully in the next 2 weeks, I'll drop this tranny and get the spline replaced.
How hard is the spline to replace? I was actually thinking of looking at my old disabled 700R4 and seeing what all was involved so I could determine if I could do it myself or if this is something that should be left to the pros.