The end of my output shaft t5 WC V8 (the part that sits in the bearings in the end of the input shaft) is really rough/wore. What I was thinking of having done is having material welded on or sleaved and re turned down to make it a sutable surface again. first off has anyone run into this and does it seem like a reasonable alternative to a $250 main/output shaft. Secondly I am trying to find the specs on what the diameter of the shaft should be on this end. Does anyone know what it should be or where I can look it up. Actually I would like to look it up to be absoultely sure. See Pic Below

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welding is the worse thing you can do to a piece of metal, often it is the quickest and cheapest way to get the results you want. in this case you quick and cheap fix i believe will be short lived unless you have it stress relieved and hardened correctly, voiding the economic aspect of the repair. actually just getting it welded and turned would be fairly costly. i think for the cost of a new input shaft you can find a used trans

Yes I have run into that. I think I have torn up a T-5 in every way that one can be torn up, at least once.

I tried that once..... didn't make it all the way around the block one time before it was fornicated again. That metal is very hard to begin with, and is hardened further by heat-treating after it's machined. If you don't do that, it'll be soft as butter compared to the forces that are on it.

If the mainshaft looks like that, so does the inside of the clutch gear. Your cheapest way out by far is to find another transmission.

Put a new pilot bushing / bearing and a new extension housing bushing and a new driveshaft yoke in the car; that's what tore that up, is too much wobble in the clutch gear and the mainshaft.

well I 'll have to see if I can find a used main shaft.. Maybe I can find a WC from a V6 for cheap (or maybe just the main shaft) The main shafts on both tranys are the same according to the GM parts book.

thats a common problem with the T5, I've talked to a guy, but I can't rememeber who it was, that repairs them, in the fashion your talking about....He uses special alloy filler weld, and heat treats after centerless grinding. If i can figure out who it was, I'll post the info. Alot of used output shafts you can buy from tranny guys have been reworked like that, at least they were. This was a few years back, maybe the aftermarket now is restocking T5 shafts these days.

Actually I found a place , Standard Transmissions who will repair it for like $75-90. I called my local machine shop and he said that It should not be a problem to fix(reheat treat also) for about $90. So I am going to take him the shaft tomorrow and see what he says.

novss i have found the best way to fix the nose on the shaft is to grind down the nose and then press on a drill bushing a shop around the corner does these all the time last time it was 75 dollars. that way you don't have to heat the shaft.