4:1 gears in a 34mm split case

Joined
Mar 12, 2005
Messages
2,971
Location
Littleton, Colorado
Is this a kit that came from us? Give us a buzz at the shop and we can look up your specs and make sure we sent you the right kit and parts to fit as well as discuss any install details.

Negative. Gears came from advance adapters and rebuild kit came from Georg. I’ve been hesitant to call for that reason.
 
Joined
Mar 12, 2005
Messages
2,971
Location
Littleton, Colorado
Also, called my local toyota dealer, ordered a new spacer for the idler bearings. The kit from AA includes bearings but no spacer. PN 90560-38003. Should have it early next week.
 
Joined
Mar 12, 2005
Messages
2,971
Location
Littleton, Colorado
Idler gear requires some clearance modifications as well. Haven’t seen anyone talking about that.

CD21AB6A-1639-4492-B2D2-2FC288242196.jpeg
 
Joined
Mar 12, 2005
Messages
2,971
Location
Littleton, Colorado
Made some decent progress on my lunch break today. Cluster gear is all together with new bearings. All that’s left is Finishing the case.

I am VERY close to being done with the case and I haven’t broke through...yet. There’s still time. Once I think I’m done, I do a full assembly with the transmission output torqued and the transfercase output torqued the disassemble again and check for any contact/witness marks. May be reinstalling this weekend! Thinking about building a adapter to lift it in with my floor jack.

A15CFAF3-FF5A-4E9B-8D90-00DE7B4D9C27.jpeg


27339C51-52AA-4BEB-A3F1-AE49EDF3F139.jpeg
 
Joined
Mar 12, 2005
Messages
2,971
Location
Littleton, Colorado
Finished up work early and spent another hour on the case half. I am done with clearencing and did not break through the case!

Waiting on my idler bearings spacer. And I’ll be ready for final assembly!

going to see what I can digup to try and measure the rear case half where I clearanced it. Not sure I have anything that will work.

CA7606F8-5CFB-4309-8C7F-555CAFD44123.jpeg
 
Joined
Aug 3, 2010
Messages
2,283
Location
North of Seattle, WA
Website
instagram.com
Finished up work early and spent another hour on the case half. I am done with clearencing and did not break through the case!

Waiting on my idler bearings spacer. And I’ll be ready for final assembly!

going to see what I can digup to try and measure the rear case half where I clearanced it. Not sure I have anything that will work.

View attachment 2463742

you can spray the inside with paint to help mark the spots were you might have clearance issues. Assemble and rotate a few rotations.

Shouldn’t be a problem to clean it out after.
 
Joined
Jan 6, 2012
Messages
8,948
Made some decent progress on my lunch break today. Cluster gear is all together with new bearings. All that’s left is Finishing the case.

I am VERY close to being done with the case and I haven’t broke through...yet. There’s still time. Once I think I’m done, I do a full assembly with the transmission output torqued and the transfercase output torqued the disassemble again and check for any contact/witness marks. May be reinstalling this weekend! Thinking about building a adapter to lift it in with my floor jack.

View attachment 2463648

View attachment 2463649
May want to modify the breather too while it's on the bench for water crossings.
 
Joined
Mar 12, 2005
Messages
2,971
Location
Littleton, Colorado
On your last picture of the split case open. Can you give me a quick explanation of where you had to clearance the case? I see two spots on the left? Is that it?

Bhsdriller highlighted them all.

The two on the left are for the Idler gear, which I haven’t seen anyone talking about. I didn’t do as nearly a nice job on those as I did for low range gear.
 
Joined
Mar 12, 2005
Messages
2,971
Location
Littleton, Colorado
Here’s some pictures of a 38mm case that Valley hybrids did. Much nicer than my case, but I don’t have access to a mill.

I used a combination of a flap disc on an angle grinder and a 36grit Roloc disc on a 90* die grinder





46F25184-30FF-4CE4-945D-F3A2F6300554.jpeg


clearance 3.jpg
 
Last edited:

Users who are viewing this thread

Top Bottom