2 questions

[chicago]

Is rebuilding the tranfercase a really hard job? I was sitting in my office (the s***ter) and thumbing through my chiltons manual, and they dont even get into the xfer case rebulid stating that it is too difficult to get into in the book.
I have 220K on mine...It functions perfectly, but lowtide mentioned "probably" needing one at 200K...that statement causes me some alarm.
Looking at the diagram above...looks pretty hairy!

Chicago

 

[calfj60]

I would suggest getting the factory manual if you are going to tear into it...I was kinda timid the firts time but I have had a split csae apart so many times I can do it in my sleep...Actually kinda fun and builds a new level of comfort...

 

[chicago]

Man, Ive REALLY gotta get those...
If nothing else, it would make for good reading material in the John;p

Chicago

 

[calfj60]

It sure does....makes things sooooo much easier....

 

[lowtideride]

Is rebuilding the tranfercase a really hard job? I was sitting in my office (the s***ter) and thumbing through my chiltons manual, and they dont even get into the xfer case rebulid stating that it is too difficult to get into in the book.
I have 220K on mine...It functions perfectly, but lowtide mentioned "probably" needing one at 200K...that statement causes me some alarm.
Looking at the diagram above...looks pretty hairy!

Chicago

Well i'll go first and if i dick somthing up I will let ya know what not to do

 

[sixty]

I have no leaks in mine yet installed gaskets dry with loctite on the threads.

Rebuilding the case is only slightly more difficult that separating it and putting it back together. The hardest part is pulling the bearings off of the main shaft & pressing them back on. With a press and a bearing puller its MUCH easier. I used a big hammer & brass drift and it worked fine. also dont waste your time trying to pull the pilot bearing, just grind it thin with a dremel and then chisel it to pieces.

Download the factory manual off of birfield.com for free.... its well worth it!!

I use a Gregories manual and its great also.

 

[Mace]

Considering how much luck I have with mini tcases dry I am leaning towards that route..

Factory manual is on Birfield.com??

cool, I'll do that now..

The tcase goes back together tomorrow and I should have the shifters done too..
Hopefully the are swanky

 

[calfj60]

I look forward to shifter pics....

 

[Mace]

So do I

 

[Mace]

damnit

I am in the middle of putting my tcase back together and you throw a fit and delete the exploded diagram. Thanks..


Can't get the birfield.com stuff to work..

 

[zcruiser]

"Now that's just mean."

- Payback, the movie

 

[Mace]

Got almost everything back together. It really is not a hard job. BUT, My caveat free lifestyle has failed..
I seem to have a spare part....

the rear output looks to be correct but I have this spacer that I cannot figure out where to put...


It is the spacer that is next to the rear output
Also, does the sequence on the rear output look correct?


BTW, do most 60's have the PTO gear replaced by a spacer?

 

[Mace]

Allright, it looks like the beveled spacer is used on the speedo gear. so, WTF is the other spacer for? or is it not a part of the stock toyota tcase?


There is also a small shim that went with it. The spacer fits the trannt input and output shaft like a glove. But it sure seems like an extra part...

Can't be for the idler shaft (too big)

 

[woody]

pics

 

[sixty]

The flat edged spacer you have in you pic goes on the main input shaft between the big nut and the input gear. In the diagram above it shows a shim in between the speedo gear and the rear output flange. I don't recall having one of those but its been 3 weeks since I assembled my case, so I may have forgotten.

 

[Mace]

I actually figuerd it out.

The flat spacer goes on the input shaft as a spacer that holds the 1st gearset (the one that has the input seal on it) at the right height. It is replaced with a slightly thinner one that AA provides ya with the 203 adapter.. I hate extra pieces and a serious lack of install stuff..

I do not have a PTO gear in this tcase at all, which seems kinda weird. Just one big spacer..

 

[Toadhopper]

Got mine from cruiseroutfitters.

All I needed was a seal kit.

Bearings and idler shaft were peachy..

MOst of the time with the toy tcases you can get things apart with a bearing puller, but a press makes things oh so much easier

I couldn't get mine apart w/a puller so I brought to a machine shop.
Well worth the $$$ IMHOP