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  1. A

    Fairey OD help needed

    It was the aluminum threads in the upper half. It was one of the long bolts next to the TC. I was going to install a Time-Sert but the machine shop suggested a heli-coil since the bolt won't be taken out regularly (or ever again hopefully). It was an easy installation and seemed to hold well...
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    Fairey OD help needed

    It's taking me longer than expected to get things buttoned back up. When I went to install the lower half of the OD I found one of the bolt holes had stripped threads. I repaired those and got the OD back together and filled with oil. The water pump was going out so I replaced it. While it...
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    Fairey OD help needed

    I can't believe it....I actually got the roll pin driven in without pulling the OD or lowering the transfer case!!! It actually went better than I expected. First off, the roll pin is 5mm. It isn't as tight of a fit as I was expecting but I think that definitely worked in my favor when I...
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    Fairey OD help needed

    I had a few minutes so I figured I'd attempt to get the roll pin out of the shaft. To my surprise, I touched it with the tip of the punch and it fell out! I guess it wasn't a very tight fit. I'm going toto get a new roll pin tomorrow and see if I can drive it in. I think it will work but will...
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    Fairey OD help needed

    Its a tough call if I can't get that pin out without remove the shaft from the OD housing. The floor has never been apart and it will be difficult to get to the bolts under/behind the heater and A/C unit. I feel like it would be easier to lower the back of the transfer case by 2", but honestly...
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    Fairey OD help needed

    @Living in the Past THANKS for taking the time to look into it for me!! I had an hour tonight so I decided to see how much damage I could do. It took a bit but I was able to get the shift fork shaft and fork out. (After you remove the detent spring and ball you have to keep the fork in...
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    Fairey OD help needed

    OK so I've been thinking about this OD situation pretty much non-stop and I'm hoping someone can clarify/verify my idea. From what I can tell, I need to pull the entire gear assembly out of the OD to get that pin reinstalled. Is that correct? Can I get to that pin without completely removing...
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    Fairey OD help needed

    Wow @Living in the Past that is quite a collection! I wish I had a few of those parts...or a spare OD. I'm lucky that mine looks really good inside. Now I just have to figure out what it takes to get to that dang roll pin without messing up the rest of the OD.
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    Fairey OD help needed

    I didn't get a chance to work on it yesterday, but I've been thinking about it a lot. I'm guessing that the detent for the shift for was gummed up from sitting for so long above the oil level and when I tried to engage the OD it bent/sheared the roll pin. That's the only way I can figure that...
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    Fairey OD help needed

    Well I found the issue....I think. Now hopefully someone can tell me what to do to fix it.... I drained the oil this afternoon and filled the TC and OD with solvent. I then took my 16 year old daughter around teaching her to drive stick. I didn't try to shift the OD....just drove it around...
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    Fairey OD help needed

    Thanks for the pic @Living in the Past So it looks like its super simple to drop that lower half to get my eyes on the fork/syncro/shaft if the solvent trick doesn't solve the problem. Hopefully it won't come to that but I feel better knowing I shouldn't have to pull the engine to look inside...
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    Fairey OD help needed

    So I crawled under the FJ40 again and looked a little more at the situation. I really can't believe how much higher the fill plug on the OD is compared to the fill plug on the TC. There is literally no way you could fill through the TC plug and have it run out the OD plug. I'm hoping to get...
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    Fairey OD help needed

    Here's something I find interesting in the manual that @Ming89FJ62 posted above. It states on another page of the manual that the oil is shared, but step 52 says to fill the gearbox and transfer case and then step 53 says to fill the OD as well. Just something I found interesting. I stopped...
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    Fairey OD help needed

    @Ming89FJ62 You're right...that's AWESOME!! Thanks a TON! @Living in the Past If I'm looking at the parts drawings right it looks like #38 is the fill plug??
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    Fairey OD help needed

    @Ming89FJ62 So what's the chance that your manual is for an early 3 speed version?? 🙏
  16. A

    Fairey OD help needed

    @Living in the Past Funny you should mention the cross member. I noticed that it has been cut out and re-welded (not very well I might add) and I assume that was when the dealership installed the OD. I'm probably going to re-do it with sleeves on both ends at some point. Even though this...
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    Fairey OD help needed

    I got the vehicle on jack stands on the right side but didn't have time to actually do anything else last night other than take the picture. I've never looked at one of these units on a bench (in fact I didn't even know they existed until I bought this FJ40) so I'm not sure how to proceed, but...
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    Fairey OD help needed

    @Living in the Past Here is a picture looking from the back of the transfer case. The fill plug is right next to the words cast in the housing. There's a copper crush washer under the plug...looks like I need to replace it. It sure looks higher than the fill hole for the transfer case so not...
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    Fairey OD help needed

    @sogncab I didn't think there would be hatred.....unless I said how much I paid. 🙂 He said $9000 when I knocked on the door and I gave him exactly what he wanted. 😁
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    Fairey OD help needed

    Ok so here at the local parts store they have 80w-90 and 85w-140. Would the 85w-140 give me good cold weather performance AND a heavier oil to help with noise? Also...is synthetic good/better in these older gear boxes??
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