3 speed T-case woes (removal)

[DesertFJ40]

So I began the process of converting from a 3 speed to a 4 speed transmission. I wanted the lower geared 3 speed T-case, So i attempted to pull it off from the original 3 speed transmission. Everything was going good, except that, once I started to pull it apart, the rear transmission bearing and gears started coming out! Im not 100% sure how exactly it happened, but im assuming that it was because the transmission was still "in gear" and not in neutral when I was separating the two. My question is, how should I proceed to take it off? will grinding the bearing off be required? Bigger hammer? It just seems the more I try to separate it, it just pushes the transmission housing back, not the actual transmission output shaft out from the trasnfercase, if that makes sense. But pretty unlucky. Also, I tried taking off the top plate cover, but it wont come off. The column shift lever is still in gear and its catching on something when I try lifting it off. I can wiggle it up some, but not enough to see what's in there. Here are pics. Thanks for the input

 

[DesertFJ40]

Hmm, well I suppose I got my main issue figured out after studying the situation a bit more. I didn't realize there was a big ol' nut that needed to be removed on the back side of the T-case (where the nose cone goes). It requires a size 32 socket. I wrapped some flat webbing around the shaft thats sitting in between the T-case and transmission to keep it from spinning. Im holding tension on it and it seems to work while im attempting to loosen that size 32 nut. But now the transmission is flopping around in place. This will be a battle I will take on tomorrow and post the results. Im sure someone will find this useful if they run into the same problem.

The Big ol' 32 size nut

Flat webbing wrapped around shaft to provide tension to keep it from spinning

 

[raiderfan]

How did it go? Getting ready to drop and separate mine here soon.

 

[Mark Jennings]

It’s not abnormal for the bearing to come out the back of the transmission when separating. The T-Case actually holds it in place when assembled. So if you got the nut a sleeve off, it’s just a mater of pushing the transmission output shaft through to rear bearing. Keep in mind that the T-Case drive and PTO gears will drop off the end of the shaft once you pull the transmission output shaft from the T-Case.

 

[Living in the Past]

You need to remove the nut, washers and spacer before using a puller. You can't slide the transfer case off the transmission output shaft with the nut still threaded on.

 

[DesertFJ40]

How did it go? Getting ready to drop and separate mine here soon.

So i was not able to do it the way i wanted to. even tried jamming wooden wedges into the opening of the transmission to keep it stabbed in place, but still nothing. Luckily, i was able to go to my grandfather's shop and the nut was removed easily with an air-impact drill

so @raiderfan , be sure to loosen up that output shaft nut before trying to separate the T-case and transmission. It should be easy using a breaker bar and some muscle. Its a size 32mm socket. Not sure if the forum posts i was using as reference mentioned loosening that nut, but either way, i overlooked it and ran into the issue above. Hopefully your transmission bearing doesn't come out like @Mark Jennings mentioned. For the most part, mine was able to separate rather easy using the puller until i encountered the problem. And as mentioned, the gears do drop off the end.

Also, be advised, since you might decide to do the whole clutch, pilot bearing, work etc., Order this pilot bearing Nachi 5202Z. You can find it on ebay and it also goes by several other brand names. 5202Z is the main bearing number, just make sure it says "made in Japan." It a fatter pilot bearing than what is sold nowadays for our Fj40s. A quick read about it HERE

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