67 FJ40 Overhaul (Burned Up...)

[kevos37]

Forgot Picture, It was a dandy!

 

[65swb45]

I took your t-case in to work today Kevin. When I picked it up, I expected to hear the familiar rattle of the front shift collar. Not hearing one, I looked inside the nose cone. No collar!

No worries; it was in the other box of stuff you left with me.

 

[kevos37]

I took your t-case in to work today Kevin. When I picked it up, I expected to hear the familiar rattle of the front shift collar. Not hearing one, I looked inside the nose cone. No collar!

No worries; it was in the other box of stuff you left with me.

I saw that before I brought it down, I was going to install it but I figured you would have it apart.

Thanks Again! Can't wait to get them installed.

Kevin

 

[65swb45]

Didn't get as far with this as I had hoped. Lots of little things to side track. I'm really glad you asked me to reset the gears. One of the things that has been second nature to me for a long time (~30 years) is making sure the thrust washers for the idler gear have enough tooth to sit firmly in the slots provided for them in the case. This wasn't a big problem in the early days, when OEM thrust washers were the only thing out there. The aftermartket thrust washers just don't have as much tooth.

OEM washer and shim

 

[65swb45]

Aftermarket

 

[65swb45]

Solution: I use a flat chisel and a piece of bar stock slightly wider than the tooth as a stop and bend the tooth out.

 

[65swb45]

And a picture of your homemade bushing for the high speed gear.

 

[65swb45]

I have never used one of those nose cone rings on a tcase here, and as I was reassembling that part of the case I became curious if it was even compatible with the vacuum shifter. It is not.

We will talk when I return from Vegas. Until then, one last shot, paint removed from critical mating surfaces:

 

[kevos37]

Nice progress pictures, thanks.

 

[65swb45]

Ok. So here's the deal with this cone reinforcement thingy. It appears it would work with a floorshift front wheel drive. But it definitely does not fit with the vacuum shift. The stud directly behind the diaphram casing sticks out too far to allow the box to slide back into location. Then, even if it were exchanged for a bolt and the diaphram housing ground into, the access plug on the backsideo of the box would hit the ring before the mounting holes lined up.

 

[kevos37]

Well that's a drag ! . Will the currently installed studs work once you delete the ring, or do you need the correct bolts to marry it up ? I included some extra hardware. If need be, I can send you the correct hardware out of my plated fastener arsenal.

Kevin

 

[65swb45]

Removed the ring and the one stud; all is well. Installed dual seal speedo housing. Pulled out two boxes of hi-lo shift forks

and got you a decent lo-mileage one to replace your worn out one.

 

[kevos37]

Looks Great Mark!

 

[65swb45]

Mystery solved!

Add this to the 'just when you think you've seen it all' files.

The reason your parking brake shoes would not retract is because the adjuster was jammed up against a piece of metal on the shoe that isnt supposed to be there.

First pic shoes the open space between the edge of the shoe and where the shoe backing plate starts

 

[65swb45]

Second pic shows the adjuster jammed against the excess metal, with the caliper to show how far the metal overhanges past the factory shoe

 

[kevos37]

We're the shoes for a different model or were they made incorrectly ?

 

[65swb45]

We're the shoes for a different model or were they made incorrectly

This is a fair question. As I told you on the phone when this drama unfolded ( couldn't get Kevin's drum off the backing plate) the thickness of the main rib in th shoe was the only change I had ever noted in my decades of working on these. So once I cut off the protruding metal to test my theory that this was the root cause of the problem, I grabbed some of the shoes I stock from the shelf for comparison.

Third photo shows the relief cuts I made in the one shoe for the adjuster to clear, along with one of my shoes dressed over the top of the opposite shoe, to illustrate the extra metal on the shoes you purchased.

Clearly the part was made incorrectly.

Sorry for the chips in your paint. I have NEVER had to wrestle a parking brake drum off of an uninstalled backing plate...ever.

 

[kevos37]

Yea Mark !! I had no idea.....):

 

[65swb45]

Yea Mark !! I had no idea.....):

As a vendor, I know it's only a matter of time until any of us end up selling something that isn't up to par and requires tweaking. Look at what all the shops have had to go through that sold Orions.

Let the vendor that sold you the shoes know about this problem and see what they have to say.

Sheit happens. @fjl40 can tell you about the Machine shop engine with the oil pressure regulator installed backwards!

 

[kevos37]

I will contact the vendor for their take on this. Thanks.