Basic question about transfer case rebuild.

[jbrnwa]

Hi, I think I am thinking about attempting my first transfer case rebuild, but before I commit I have a question:

After I tear this thing down I will obviously need to decide which gears and shafts can be saved and which ones can't. What does one look for to determine whether or not a gear or shaft is in good enough shape to keep? Will I need a trained eye to tell me this?

Thanks!

 

[2mbb]

Why are you rebuliding? Is there a mechanical problem, or just leaking?

A visual inspection of the gears for chips, uneven wear, etc. is pretty straight forward. The FSM also has other inspections to do, as illustrated below. If you don't have a copy of the Body and Chassis manual you should purchase one or download one from here: Master Portal - forums.bauchan.org/Downloads - page: 1

Replacing gaskets and seals isn't that difficult. replacing all the bearings is a little more difficult and requires some specialized tools--pullers, press, etc. Inspecting for clearances, requires more stuff. Good luck.

 

[jbrnwa]

Thanks 2mbb! I do have the FSM. I've pulled apart a lot of landrover transfer cases, but never a landcruiser case. I've never known how to properly inspect them, much less reassemble them. Thanks for the heads up on the special tools. I had a feeling...

 

[lehiguy]

It's not very difficult once you get used to the fact that it will have to be removed one piece at a time and put back the same way. Getting the range selector into place while installing the back half of the case is a bit bothersome, it helps to have an extra set of hands. When you take it apart, do not allow the idler shaft to pull out, unless you want all the gear lube from the transmission to dump on you. You will most likely want to replace that shaft anyway, so drain the trans first.

 

[Cruiserdrew]

The idler shaft comes as part of most of the rebuild kits, so definitely replace that! The output shaft can normally be reused. The two I've done, it's looked brand new. If the surface that the output gear bushings ride on is scored or scratched, then I would replace it and the brass bushings on the gears.

The FJ62 t-case actually has bearings on the output shaft gears, rather than the brass bushings. That looks like a desirable arrangement.

To do the rebuild, I highly recommend you drop the transmission and t-case out of the truck. As mentioned, the high/low range selecter is difficult to get in the right spot, and it is possible to put it in wrong and close up the case without knowing. In the truck, it's that much harder.

 

[Mace]

On shafts, if they look worn, they need replacement