Stress raisers on worn output shaft

Hi all
After my supposedly refurbished r380 300tdi gearbox went caput, I’ve had to take a gamble on a reasonably good second hand one.
There is a small amount of wear on output shaft, as in the photo.

From looking at other threads I get the impression it won’t be too noticeable with that amount of wear?

My question is, as I’m mating it to a different transfer box than the one that’s done the wearing, should the input gear overlap onto the un-worn shaft a tad, could this stress and break the end of the teeth on the input gear??

Is the input gear in your replacement transfer box a cross drilled one?

tottot said:

Is the input gear in your replacement transfer box a cross drilled one?

Click to expand...

Yes

That's good then, the shaft will get lubed. If your old transfer had a non drilled input it would have accelerated wear on gearbox output shaft. Even so what you have is very little.
The splines in a cross drilled input gear are longer than those in a non drilled one so if drilled replaces a non drilled one some of the spline length will engage with un worn parts of out put splines so extending life.

tottot said:

That's good then, the shaft will get lubed. If your old transfer had a non drilled input it would have accelerated wear on gearbox output shaft. Even so what you have is very little.
The splines in a cross drilled input gear are longer than those in a non drilled one so if drilled replaces a non drilled one some of the spline length will engage with un worn parts of out put splines so extending life.

Click to expand...

Ok, but that would mean all the load transfer through the small unworn bit, until it wears? I’d there no danger of the high stress cracking things……or am I over thinking things?

All I can say is that have done this on a couple of landy's and they are still working several years later, one had a shaft with much more wear than yours. I do not think stress is an issue as have not known a shaft break, they just wear until splines are so thin they fold and there is a nasty rasping sound.
It is a poor show that JLR allowed the same fault, lack of lubrication with the MT82 box output shaft in Tdci models with the same result.

Cheers for the advice. Will go with it.

Out of interest who 'refurbed' your gearbox ?