lefty1,
Like Tommy says, don't remove the input shaft unless you follow the proper steps. Otherwise the roller bearings will drop down into the case.
This next photo shows the design of the IS. It has a partial cutaway to allow clearance of the cluster gear during installation onto the mainshaft.
The cutaway portion is seen at the lower section of the IS piece in my hand and is slid into place with the orientation I show in this photo. Of course, this photos has everything outside the case for clarity.
IS with cutout area lined up with cluster gear.As far as swapping the IS goes, you must match the tooth count for each. If the original S10 IS has 21 gear teeth (we're talking teeth here - not splines) then you would need to swap in another IS with the same tooth count. You might think that it might just be as simple as swapping in an IS from a V8 Camaro or Astro van, but that does NOT work unless the gear teeth count is exactly the same.
If I could swap a Jeep IS into an S10 T5 and eliminate the adaptor plate and wouldn't need to cut the shaft or lengthen the IS splines, then I guess I'd do it.
If I'd still have to cut the Jeep IS short or use an adapter plate, then I see very little benefit to swapping. Sure, you could keep your 10 spline clutch disc and original pressure plate, but that's all.
This next photo shows the IS in my hand with the cutaway near the bottom. The gear visible through the hole in the case will mesh with the IS. The cutaway must be lined up with that gear for clearance during installation. Removal requires removal of the bearing retainer and then lining the cutaway up with the cluster gear. Then it can come out. The roller bearings inside the IS may or may not fall into the case during removal, so having the case lid off is recommended.
Line up IS cutaway with cluster gear. Disclaimer: I don't know why, but I have a passion for the T5. I'm not an expert. I learn new stuff all the time. Before I rebuilt my T5, I watched professional videos about how to rebuild them and was given professional advice. I'm confident that I understood and did each step correctly. I welcome you to visit my website
T5 PAGE which has a large section devoted to the Chevy version of the T5. I have gathered a lot of good information there and I hope to add more as my knowledge increases.
Jay
