2F into a 72 FJ40 need transmission advice

[MoCoNative]

Here is some info on it, I know there is more out there.

4speed bolts for FJ40

Does any one know the longer bolt size for adapting a transfer case to a 4speed transmission for an FJ40? Are better yet have some. I need three of them with the washers. Below is a photo from SOR. It's number 1 in the photo.

forum.ih8mud.com

I remember what bolts are a different pitch, but I think you have some. The tranny to bellhousing bolts are different between the two tranny systems. If you use the Toyota part numbers above, I know I got some through Toyota, but I'm pretty sure the long one was NLA and I sourced it used.

Big nut should be sourceable through Toyota also. Some hardware items are cheap through them, and some are expensive, just depends.

 

[4Cruisers]

Nut: Toyota Part Number 90179-20061, retail $10.20 each. I'll see if I have a used one in my box of parts.

 

[4Cruisers]

Didn't find one.

 

[96 Bronco]

that part# was correct. I'm attaching the exploded view from Toyota (parts man sent it to me) for everyone's use. i was attempting to also order the spacer that's at the end of the shaft directly in front of the nut in question, and according to this diagram there is not one on the for 4 spd. My 3 spd has a pretty big spacer in that location (like 2" long spacer)

 

[65swb45]

I have the hardware and spacers packaged into a deluxe adapter kit. It’s listed in the classifieds, but the search isn’t working for me to attach a link. :-(

 

[96 Bronco]

search isn't working for me either. I'll be attempting to mate the 4 spd transmission and the 3 spd trans case in the next couple days so i will call and order whatever I'm lacking if its still available. Toyota dealer local to me has that output shaft nut available.

 

[65swb45]

search isn't working for me either. I'll be attempting to mate the 4 spd transmission and the 3 spd trans case in the next couple days so i will call and order whatever I'm lacking if its still available. Toyota dealer local to me has that output shaft nut available.

I'm sorry if I wasn't clear. If you are piece-mealing, I will not be able to help you. The parts are only available from me as a complete kit.

 

[Dizzy]

From the back of the transmission bearing to the back of the transfer case under cover No. 2 : Input gear stopper, 4-speed-splined input gear, spacer (or PTO gear), bearing, input shaft spacer, 4-speed washer (but thick enough that it could be mistakened as a spacer), (new) staked nut. Correct me if I am wrong.

 

[96 Bronco]

Anything obviously wrong here? Transmission output still turns with transmission in neutral and transfer case installed. Motor is in and I’m ready to start it up but I’m afraid it’s gonna jump forward

 

[96 Bronco]

Motor fired right up but the trans is definitely stuck in gear. Any help please. I believe the person on mud I bought this from was honest and that is was running fine before. Did I maybe pull the shifter without it being in neutral? See my pics above of inside the trans, I don’t know what it’s supposed to look like

 

[Dizzy]

Well, I don't know.

Can you pull the case cover assembly, or is the tub in the way? Use penetrating oil on top of the thru holes on the case cover because those dowels are a bit tight and you don't want to tear a gasket with a prying tool.

The image below is a configuration of neutral. Notice the Hub Sleeve location.

It is not impossible that the shift fork was placed incorrectly relative to the hub sleeve when the case cover was off. It looks a bit off from the image up top that you posted.

Are you able to cycle thru the five gears plus reverse with the shifter?

 

[Dizzy]

Notice how thru the shift tower, those tabs are almost perfectly in line on mine.

 

[96 Bronco]

I can only get R, 1,2, and 3 right now. I did notice mine isn’t perfectly lined up. It’s all the way installed, but my tunnel is out I can get to every thing from the top.

 

[96 Bronco]

Well, I THINK the problem is in getting the shift forks lined up correctly. Operating the gears with to cover off and a screwdriver you can isolate the issue. I can not get into 3rd or 4rth gear. They all sort of return to neutral - which I’m assuming is where the reverse fork comes to rest - it is spring loaded and always moves a bit. I’m aligning the others with this one. The shifter handle goes in easily, in the neutral position, I can grab 1 st and 2nd and reverse easy, but I’m kind of forcing 3rd and 4rth is just blocked

 

[Dizzy]

Is it possible to remove the case cover with the shift tower attached? Or do you have to pull the transmission?

 

[96 Bronco]

You could I guess. But the shifter would just flop around. I’m confident the three rails are all set to neutral and I’ve put the shifter back in. I’m going to finish motor install and run it with the clutch depressed and see if I can cycle through the gears. I’m likening the problem to it being in between to points and need to rock back and forth to find home? Wishful thinking?

 

[Dizzy]

In the case cover, you will find everything that normally governs the geometry of the shifting forks. I'd investigate this side of things.

The shift lever retainer clamps down on the case cover and it places load on three compression springs. Those appear to be missing in your photos above?

 

[Dizzy]

Balls and springs go here.

 

[96 Bronco]

I have the balls and springs back in place. I just set the springs aside when I pulled the cover

 

[96 Bronco]

And in the photo dizzy attached, that is what I’m asssuming the neutral position is