[Oliver25]

Hi Folks,

new here, have always been in the abckground reading. I am Oliver and own a Toyota 1985 LJ70.

Currently refurbishing the tranny and transfer case. So far so good, all needle bearings, synchros, main bearings and c-clips were exchanged in the tranny.

As for the transfer gear, I figured to install a new rear output shaft, needle bearing and a new idler shaft with needle bearings - as well as all shims and main bearings.

The thing is, my output gears for high and low speed are isntalled on bushings. I didn't find a part number in the EPC and in my repair manual nothing is written about bushing exchange. However, both bushings are worn, especially the low gear one which is spinning always as it's engaged maybe 2 % of the run time.

I found the parts over in Down Under with parts number 90999-73089 - not exactly epensive so I added them to my parts list.

The new rear shaft has the exact same dimensions as the old one - I pressed out one bushing already and isntalled the new one. On one side, they are 4mm longer making them sit a bit in the oil cut (tapered roller bearing side) The overall gear width is 4mm wider than the new bush. I figured it shouldn't be a problem as there would still be oil going to the bushing via the cuts - furthermore the output shaft sits in oil all the time.

After pressing the new bush in I noticed the diameter was too small to make the gear go on the shaft. I took some 220 grit sandpaper and put it on a round wooden stick, spinning the gear with new bush on it to sand it out evenly (good idea or not?).

Now the bush goes on and you get some oil inbetween to run on, however how much difference between shaft diameter and bush inner diameter should there be? Now I am at around 5/100mm difference, dry. I don't want the lubrication film to get cut off (possible?) and let the bush run on the shaft. Should I polish it out more? I finished off with some 400 grit to even the surface a little bit - should i go further, and maybe even use polishing paste for fine finishing the bush?

Any reason for the bushings to be not in the EPC/repair manual? They gotta be exchangeable as a 500$ bill for a new gear in perfect condition just because of a worn bush sounds silly to me... I found the bush in the HJ60 EPC - however, I don't have a repair manual - oes Toyota describe in different transfer case repair manuals what measurements the bush has to habe?

Would be great to hear some opinions on this one as I didn't yet install the low gear bush... and still am not 100% on the high speed bush.

Cheers and many thanks!

Oliver

[Radd Cruisers]

The bushes are available and they do need to be reamed to provide oil clearance and a proper fit.

The oil clearance is as shown here... both gears are the same for clearance...

[Oliver25]

Thanks mate, that's the difference between German and English repair manuals - here it doesn't say anything about oil film clearance but only maximum play that's allowed before having to exchange the bush.

I have read around a bit and now figure the best thing is to either use a reamer or a hone tool like we use it for brake cylinders. What do you think about my first idea with sanding paper wrapped around a round wooden stick?

So to my understanding - the clearance level minium is the measurement I have to achieve without oil between shaft and gear and with a newly reamed bush, right? The max play would also mean without oil but it most possibly would also have a play with the oil film in place. Am I right with my assumptions?

Thanks!

Edited to say: Funny, the oil clearances in your repair manual are a lot bigger than in my manual. With mine, the max play is 0,060 mm and here it says 0,081mm