90 HDJ80 MT shat the bed (1 Viewer)

[Stiles]

Awaiting a tow truck, researching what may be my problem:
Sitting at uphill intersection, truck got started in first gear, then something went awry rather suddenly with a deluge of grinding noises and no propulssion.

Can move tranny thru all 5 gears and reverse. Upon letting out clutch there is only awful loud unpleasant grinding. Clutch l hope!

1990 HDJ80 at 270k km with manual tranny

Troubleshooting assistance appreciated to the max

 

[ZCissner]

do you have the transfer case halfway engaged?

 

[TRFarmers]

I'll take throughout bearings for $100

 

[duncanrm]

I'll put $3.20 on a broken rear axle.

 

[Stiles]

do you have the transfer case halfway engaged?

I moved in and out of 4H and 4L with no change.

Was just on the beach in South Padre and the CDL didnt engage for a day. But functioned normal today, and when switching to 4L after the breakdown. So l -think- tcase isnt the issue. The CSL issue was a curiosity.

All these problems are new to me. Had this truck for 40k km. All the fluids have about 30k on them.

I like what l'm hearing about potential avenues to explore, here. Thanks MUCH for the educated speculation!!

 

[Stiles]

Sunday morning, beach. 400miles later Sunday night: tow truck the last 35 miles home. Blessed to have made it pretty damned close!

 

[Stiles]

No metal in transfer case fluid. No metal in transmission fluid. Clutch feels strong.

Transmission will begin to move vehicle until clutch fully out, then slips somewhere and makes a godawful grinding. Sounds like from the rear output of tcase.

With all four wheels in the air everything operates smoothly, with no grinding in 4hi, 4lo, cdl, and front and rear locked. Made the slightest clunking/momentary grind when locking cdl for just a moment. No noise in operation on or when turning drive shafts or wheels when off.

Still trying to identify my problem... any advice on what to do next? Pull transfer case?? Splines on output shafts seem a likely culprit.

Thanks, muddah mechanics!!

- Joe

 

[bug616]

I’d say it’s your transfer. See here What broke in my transfer... - https://www.landcruiserclub.net/community/threads/what-broke-in-my-transfer.146413/

 

[Stiles]

Awwww, s*** :/

Thanks, bug. That does seem my issue. Now the question is the best fix: buy a new aftermarket case from Australia? I've had no luck tracking down an oem case or one in the States.

 

[bcsteel]

There are vendors on here that can help with tcase I imagine. @orangefj45, cruiser outfitters ….

 

[cruiseroutfit]

Awwww, s*** :/

Thanks, bug. That does seem my issue. Now the question is the best fix: buy a new aftermarket case from Australia? I've had no luck tracking down an oem case or one in the States.

Full-time (assuming as you mentioned CDL) on an 80?

No problem. We have used cores and rebuild kits. We can send a rebuilt and/or regeared case.

Or, can send you a brand new HF2A case with stock gears, low range gears and/or high range overdrive/underdrive gears. Info@cruiseroutfitters.com

 

[bcsteel]

Now that’s service!

 

[Stiles]

Now that’s service!

Daaaamn! Boy howdy. That IS service, with a smile to boot. I've been sweatin this a bit.

When youre lookin for your friend in a crowd, it sure helps out when they stand up and wave at you

 

[orangefj45]

Feel free to call us before ripping the cruiser apart ………. this might be a fairly simple fix.

Happy to help.

Georg @ Valley Hybrids @ Cruiser Brothers

PS: we build lots ( AND LOTS ) of these transfer cases.

Shop 209-475-8808
Sales@valleyhybrids.com

 

[Stiles]

This is what l'm talkin about! I wish l could buy a round for the helpers gettin me started

 

[mudgudgeon]

Was just on the beach in South Padre and the CDL didnt engage for a day.

Are you sure the CDL is locking in low? If you've had trouble with it, it may be part of the problem, but maybe not the cause

Have you checked the front hub drive flange/birfield splines?
It's quite common for these to flog out on early 80s.
When it happens, you'll lose drive, and have grinding noise through the drive train.

The location of noises can be deceiving, particularly when we think we've figured out where it is. Not saying you're wrong about the location of the noise, just saying some more investigation might be worth your while.

If it's front hub splines, your talking $300ish in parts per side vs 1000s for a transfer case. And if you miss stripped hub splines and rebuild the transfer, you'll still have to deal with hubs.

 

[Stiles]

Would it be yall fine fellas think it prudent to replace the clutch while l am working on tcase? I've driven a manual for a few decades and never had to replace one.

Truck has 170k miles on it. Came from a rental fleet in Spain, so a bit more compromised than a regular clutch, l'd reckon. An idea l had, since l will be removing transfer case and be partway there...

 

[Squash]

As above, check the front axle drive flanges. You want to shift the transfer case while in Neutral to avoid noise.

 

[Stiles]

I was walked thru a test with a specialist: he told me if the front drive line rotates as the tru k sits still that the front drive splines are the issue. Since it did not, he said it was a problem in the tcase.

Is there another check of front axle splines l should execute? I'll start searching on here...

The cdl locks as it should, so l would guess that even if front splines stripped, the rear drive locked would still push the truck, which it does not.

 

[mudgudgeon]

I was walked thru a test with a specialist: he told me if the front drive line rotates as the tru k sits still that the front drive splines are the issue. Since it did not, he said it was a problem in the tcase.

Is there another check of front axle splines l should execute? I'll start searching on here...

The cdl locks as it should, so l would guess that even if front splines stripped, the rear drive locked would still push the truck, which it does not.

Jack the front up, pull the dust cap off the end of the hubs

Rotate the wheel. The axle and hub should rotate together.

Video below of a new to me cruiser. There is a lot of play between the axle and the flange. Not sure stripped out, but not far off it



With one front wheel jacked up, it's easy to verify that the CDL is working. Lock CDL, put the transmission in neutral. if CDL is working, you won't be able to rotate the wheel