Help needed finding Transfer Case Parts

[jdstrickland]

Let me pose a hypothesis, The previous shaft that was worn also killed the gear that it goes into, and now the new spline has a 1/4" of good gear that is now also bad because it is so small it cannot do the work that is required.

All you need is a new spline -- you already have it -- and the output gear that it goes into. With new splines on the output gear, and longer splines on the shaft itself, you should be good to go, and no other modifications needed. You do not need to overthink this one.