81 BJ42 - I have to bring it home and pass inspection

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Yup, Kurt sent me the kit. I use RTV and the gasket together. We'll see how well it works.

All the parts are off. Time to clean and re-assemble. Most of the bolts were not terrible tight. Can't say for sure but she may have never been apart before.

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From my experience the RTV is required for that kit, not so much with Toyota gaskets.
 
what? no blasting of the case and PC?
love the looks of that bumper and the idea you will go back? as Bruce said to me one day when i was hording the parts off one of my cruisers i was modding ... "have you ever seen anyone go back to stock?"

can't argue facts, that was the end of my hording days.
 
I think the factory bumpers are still available and am thinking of picking one up in the US while down for Moab. It would hang on the wall until the frame off. The 42 will be the "city" rig as soon as the much more modded 45 hits the trail. The 42 must still perform but the 45 will be the "trail rig". Both will work both ends of the spectrum but lean in opposite directions.

New bearings on the shaft and front output. Just ran into a hiccup though. The tranny/tranfer seal is a couple mm too small in diameter??? Seem to recall this happening before in a thread on mud.

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Awl_TEQ said:
I think the factory bumpers are still available and am thinking of picking one up in the US while down for Moab. It would hang on the wall until the frame ...
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I just bought one not long ago. I think Toyota even said the chrome version was available along with most of the hardware. Some of the large round headed bolts that came in my magic plastic bags were chrome instead of cad.

I really like those stock bumpers :p
 
The Kurt kit seal is approx 2.84" dia and the case is 2.905"

I have some spare seals here shown on the right. Top is output seal, middle is the same as the one in the kit and the bottom is 2.910". The bottom one would work but it has a flange on it. Should I use it?

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The one in the kit is a double seal. Springs on both sides. The one I have that fits is single sided. I could use it facing the transfer to stop tranny oil from leaking into the transfer.
 
Awl_TEQ said:
The one in the kit is a double seal. Springs on both sides. The one I have that fits is single sided. I could use it facing the transfer to stop tranny oil from leaking into the transfer.
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I'm glad you are dealing with this now - not for your sake, but for mine. I'm about to do the same to my BJ42 transfer case next week. I am also ordering the kit from Kurt. PLEASE update with any solutions. The main reason I'm going to tear it down is that seal right there. It is pumping oil into the transmission. That, and a few other leaks as well.

I love this build!

:cheers:
 
Kevin,

I would always use the factory seals. They have the little mushroom top and I've never seen that elsewhere.

Love your bumper! Factory bumper over that? Different strokes for different folks. I'd never take your bumper off; compliments the cruiser front end perfectly. Factory does look nice, but that bumper is a step above.
 
Out of curiosity what brand is the transfer refurb kit? I had to reuse a paper gasket as the one I got with my kit was completely off. I did the smear rtv over every gasket though and it seems to be holding up for the last 20,000kms.

http://m.parktool.com/product/torque-wrench-tw-1

Look into trying to track down one of these tools to properly set your output bearings preload. You'll need one as the regular one for setting wheel bearings isn't fine enough. It will run you $70 bucks.
 
Make sure you clean the oil off the threads of the bolts that hold the case together and use some medium threadlock on them. Id also let the RTV and threadlock set for a couple days if you can before adding gear oil to the case again.

I say this as the t-case on my 80 worked loose a couple times since, even with heaps of RTV and threadlock.

Edit: BTW, I know they changed sizes of one of the shaft one of the gears rides on in the 60 series case in the later years (FJ62's), So its possible they changed parts in the 40's cases as well.
 
I had the same issue with the '83 splitcase in my 45. Not sure what I did but the photo shows I did put a seal in there.

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Though closer inspection reveals the seal appears to be riding the toybox output splines??? Wonder if I left it that way? I wonder why I would? Maybe an illusion? Does the split case even need a seal when mated to a toybox?

Oh well, one issue at a time. The 42 first. What say you gurus out there?

A) Use the seal I have even though its a "single" direction seal.

B) Order one from a dealer. They won't have it in stock. I don't really want to wait.

C) Pop in to Transmission Supply and get a double sided seal?
 
Awl_TEQ said:
Though closer inspection reveals the seal appears to be riding the toybox output splines??? Wonder if I left it that way? I wonder why I would? Maybe an illusion? Does the split case even need a seal when mated to a toybox?

Oh well, one issue at a time. The 42 first. What say you gurus out there?

A) Use the seal I have even though its a "single" direction seal.

B) Order one from a dealer. They won't have it in stock. I don't really want to wait.

C) Pop in to Transmission Supply and get a double sided seal?
Click to expand...

I'd say get the two-way seal from transmission supply...
 
Ok, an update.

I tried a local place, Transsmission Supply, who usually has about everything seal and bearing related but they would have to order in this particular seal ina 74mm and don't have a supplier for a double sided one.

The dealer can get a seal in a day from the Vancouver warehouse. Or rather two seals. I talked to one parts guy and ordered a part number I sourced off the interweb. Then after some more thought I called back and spoke to another guy and he came up with a different part number so he is bringing that one in as well. We'll see which one is right.

I posted the issue on our local RMLCA mailing list and got some uncomfirmed reports about there being some seal differences. One member replied that '88+ seals were double sided and that earlier ones were single sided. No comment on the OD size though. This would lead me to believe that the kit was intended for a later splitcase such as for a 60 or 70 series. The idler shaft was a separate package so that the main kit could be supplemented with either the 34mm or 38mm shaft and bearings.

Lastly, and I admit I should have done this first, I sent an email to Kurt, the supplier, to appraise him of the sitch and see if he had run into this before. Haven't heard back yet at this time.
 
Thanks for that. Yes, Kurt is a busy guy for sure. I hesitate to even mention him as the supplier as it is very easy on a public forum to give the impression that I am in some way miffed at Cruiser Outfitters and by extension Kurt. This is a minor inconvenience. I'm in no hurry for Kurt to take any action here nor do I consider this to be his "fault". Just sent him an email because I wanted to let him know and see if he had perhaps mistakenly sent me the wrong kit (doubt it) or something else was going on. I have a seal inbound for tomorrow at the dealer and as long as its the right one I'm golden.

There is always the possibility that I have messed up here too. To recap: there are only three large seals in the kit. Front output, rear output and the tranny/transfer seal. I have installed the front output seal, a 74mm OD unit. The rear output seal is smaller at 62mm. Did I put the inter case seal into the front output? If I did then the seal I am missing is the front output. Both locations are 74mm openings in the case. But I have only one 74mm seal. So either the wrong seal got into the kit, which was a vacuum packed deal, or the kit was meant for something else.

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This just popped up on the RMLCA mailing list as a reply to my query from a reputable source.

Quote:
My guess is the seal is different between the 34mm idler and 38mm
idler cases. The early seals sat on a splined spacer and the later
seals sat on a flange on the t-case input gear.
End quote

My seal sits on a splined spacer and it is a 34mm shaft.
 
See my email Kevin?

This might be useful here too:

There was a split in seal part numbers for the 1983 model year, up to October of 1982 (which would have been called a 1983) and later.

1980.08-1982.10 - BJ42, FJ40 90311-48002 which the seal manufacture has superseded to a 90311-48009 (74mm)
1982.10-1984.10 - BJ42, FJ40 - 90311-48007 (Measures 72mm OD)

The 90311-48009 (our part# TC48009) is the same as the front output seal so it will have the dust lip on it. Obviously this won't mate against anything inside of the t-case but it won't hurt either. We ran into this a couple of years ago with the seal manufacture and the assembler of the kits in Japan, they stand by that application. If you prefer a double lip seal in this spot without the dust lip, the Toyota 90311-48022 should do the trick. I don't have one here in stock to measure but that is what my notes indicate, unfortunately that is a Toyota only part, NOK and the other Japanese seal makers we use don't have an application for that, rather they reference back to the 90311-48009. I'm going to order the 90311-48022 to see if that has the dimensions (74mm) we want for this application.

Now as for your kit, it should have had a second 90311-48002 (which they supersede to the 90311-48009) thus giving you a total of two of those? I double checked a couple of the kits we had on the shelf and sure enough they had 2 of the 48009, sounds like yours might have been skipped over, sorry about that. Lemme know if that helps out.
 
Your e-mail will be waiting for me at work, can't access it from home.

Like I said above, I should have talked to you first! That's great info. I have two different seals ordered so likely one of each. I should be covered and if not then I now have the part numbers you provided.
 
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