I finally got this done today. The ford output slips right in place of the chevy front output. I did not have any problems with the needle bearings. Just used a little assembly lube to keep them in place. I did the swap without dropping the t-case from my buggy. Once you remove the rear cover, the complete output assembly will pull right out. No need to even remove the shift forks. Here are a few tips for those who may want to do this.
#1 Once you remove the output shaft disassemble it on a bench with a rag under it so the needle bearing do not go everywhere when you remove the Gear.
#2 A large heavy duty pair of snap ring pliers would be helpful, and make removal of the snap ring easier, but I did it with a standard pair. Just be ready to use a couple of screwdrivers to assist with removal and install of the snap ring on the output.
#3 Even though you do not have to remove the output bearing retainer on the front of the t-case to remove the output shaft it is nearly impossible to put it back together without removing it. It probably does not need to be removed if your t-case is out of the vehicle, but its impossible to get everything lined up if you decide to do the swap without removing the t-case from the vehicle. If I would have done this to start with I could have done the swap in less than an hour. Took me an extra hour to finally decide to remove the front bearing retainer, and then everything fell into place in about 10 minutes.
#4 You must use a rear output shaft seal , and a rear output shaft nut on the 32 spline front output. The 30 spline or is smaller on both parts. I ordered a complete gasket kit off ebay for about $12. (this will give you extra gaskets and seals to save for later if needed) Denneys driveshafts has the output shaft nuts for $2,25 each plus shipping.
BTW if anyone wants to upgrade from a 10 spline to a 30 spline I have everything including gaskets, seals, flange with bolts, Nut, and even a brand new cv driveshaft that I can make someone a good deal on. (PM for price)
