last chance to save me from myself!!

[amaurer]

I am putting the tranny back in first thing tomorrow after my clutch job. You guys might have noticed based on the number of threads I've started that I'm learning as I go, so thanks in advance for all your help and patience.

I'll let the pictures do the talking, these are a bunch of shots of various things so that, with luck, someone can tell me if I've done something horribly wrong.

Questions in my head:

-How much grease is too much on the input shaft splines and diaphram spring? The TSM says to grease em all, but I worry about the grease moving to the clutch...

-I've been warned to reinstall the clutch cover in the same orientation as the one I took off. Unfortunately, the only asymetrical component on the old cover was the balance weights, and the new cover doesn't have balance weights! Given the pins in the flywheel, the cover can only go on in three positions, and there is no difference on the new cover between any of them.

-My transmission was blue at one point?? I found some paint under all the mud.

And the pictures!

 

[amaurer]

new pics

 

[Colorado Boy-74-FJ40]

I like the sawhorse lift!. Great idea!

 

[zuluzeugma]

I like the sawhorse lift!. Great idea!

I second that... Thats awesome

 

[lostmarbles]

........-How much grease is too much on the input shaft splines and diaphram spring? The TSM says to grease em all, but I worry about the grease moving to the clutch...

I think by "diaphragm spring" the manual meant to say "release fingers" (if you look where the arrow in the manual is pointing).

(I've found quite a number of errors in the Toyota Manual and that's why I made the comment "it is not to be taken as Gospel" in one of your other threads.)

In answer to your question, I would say "minimal grease" verging on "none at all". (Your worries are well-founded here.)

One other thing that may interest you:
Back in 1981 at just 40,000kms, I had to replace the clutch plate on my BJ40 due to the "gearbox input shaft oil seal" failing and feeding oil right into the centre of the clutch.

This was obviously some sort of "factory seal-manufacture/installation-fault" because the new seal I fitted has never leaked since.

Since I wasn't happy with the factory design (in which the leaking oil was fed into the centre of the clutch) I drilled a hole in the base of the casting on which the release bearing slides (just after the oil seal). This ensures that any oil that leaks in the future will simply run down to the base of the bellhousing and drip on the road rather than destroying my clutch. You may like to make this modification too?
PS. Mine is an earlier production model of course. Perhaps the factory themselves realised their design flaw and have already modified yours?

 

[lostmarbles]

.......-I've been warned to reinstall the clutch cover in the same orientation as the one I took off. Unfortunately, the only asymetrical component on the old cover was the balance weights, and the new cover doesn't have balance weights! Given the pins in the flywheel, the cover can only go on in three positions, and there is no difference on the new cover between any of them......!

Oh yes. Forgot this one.

------- Don't worry about the orientation of the "pressure-plate-housing" (or "clutch cover" as the manual calls it) on the flywheel.

It is a new one - So matching it to the old orientation is completely irrelevant. ("Matching the orientation" would only apply if you were reinstalling the old one.)

 

[amaurer]

I drilled a hole in the base of the casting on which the release bearing slides (just after the oil seal). This ensures that any oil that leaks in the future will simply run down to the base of the bellhousing and drip on the road rather than destroying my clutch. You may like to make this modification too?

No they haven't changed it. How far back in there is the oil seal?

Also, speaking of the input shaft, mine has a surprising amount of play in the direction perpendicular to the shaft axis (radial). I read this thread (https://forum.ih8mud.com/40-55-series-tech/157367-h42-input-shaft.html) which says that its normal and not to worry about. Naturally this isn't going to be wiggling much once the pilot bearing has a hold of it, but any comments?

 

[aksnowryder]

I love your clutch alignment tool... I made one just like that on my lathe for mine... worked so well... I made one for my bulldozer too.

 

[lostmarbles]

No they haven't changed it. How far back in there is the oil seal?..............

I can't remember exactly. (1981 was a long time ago.) But it must be close to the g/box end because I know I was happy with my work. I felt there was very little chance of gearbox oil ever reaching the clutch again. (I remember that I couldn't work out why the factory hadn't put a hole there.)

If you plan on drilling a similar hole, I'd unbolt that housing to do so anyway. (Despite how long ago it was, I seem to remember getting away with not draining the g/box oil for this.) Once the housing is off, you'll easily see the best place to drill the hole.

I hate to increase your workload, but it would make sense to change that seal at the same time (if you do decide to drill the hole).

...Also, speaking of the input shaft, mine has a surprising amount of play in the direction perpendicular to the shaft axis (radial). I read this thread (https://forum.ih8mud.com/40-55-series-tech/157367-h42-input-shaft.html) which says that its normal and not to worry about. Naturally this isn't going to be wiggling much once the pilot bearing has a hold of it, but any comments?

Wish the heck I had MUD back in 1981! I remember being VERY worried about the amount of play I had in my input shaft. It certainly seemed excessive to me at the time.



PS. Feel free to start a new thread to ask for other people's advice on the my "hole drilling modification". (I would actually be interested to see if other people have done this or what their views are about it.)