Cracked Transfer Case Today (1 Viewer)

pb4ugo

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In this situation, I certainly would have determined that I'm not going to be using that case again. So, then the case is sacrificial, cause it's broke already. If I wanted the idler gear, I would either be cutting or busting the case up to get the internal parts out, or pounding the idler shaft out. Relieving some stress in the case might be good to get the idler shaft out too.
 
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Apr 21, 2005
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I've always managed to use the slot for keeper on the non freeze plug. Use that slot to leverage the shaft back out pass the O ring. Driving it thru and out the freeze plug side the O ring has to slide thru everything.
 
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Aug 23, 2012
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Would still need to deal with the sixteen spline verses the nineteen spline tailshaft the split case input gear has to ride on. A cheap 60 series transmission and transfer was listed in the classified lately. The four speed top cover could be switched but with the V8 the 60 series is a better fit.

Has it been determined if this is one of the 8/80+ one piece transfer cases with the large idler gear shaft like @65swb45 mentioned earlier in this thread? In the US those are a white elephant as far as finding parts. Would be 100% sure of the condition of all the internal parts before even thinking about repairing the case.
Internals not good

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Nobody said to drive it thru the freeze plug side, it was offered that you can drive the idler shaft toward the front to dislodge freeze plug so you can then tap the shaft out the rear of the case.
 
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Nobody said to drive it thru the freeze plug side, it was offered that you can drive the idler shaft toward the front to dislodge freeze plug so you can then tap the shaft out the rear of the case.


Makes sense. Never dealt with a cracked case and didn't disturbed a good freeze plug if I did have to. Engine block dealing with water/antifreeze and have to worry about rusting from the inside. Can inspect the transfer case for rust on the inside. Rusted gears (which never had in a transfer case) aluminum case is the only thing worth saving.

With the current V8 and rear motor mount would only use an Orion case. My personal choice would be a split transfer case and crossmember under the transmission for a rear motor mount.
 
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Makes sense. Never dealt with a cracked case and didn't disturbed a good freeze plug if I did have to. Engine block dealing with water/antifreeze and have to worry about rusting from the inside. Can inspect the transfer case for rust on the inside. Rusted gears (which never had in a transfer case) aluminum case is the only thing worth saving.

With the current V8 and rear motor mount would only use an Orion case. My personal choice would be a split transfer case and crossmember under the transmission for a rear motor mount.
Worked perfect. Not much force either. One wack n out pops the plug the 3 or 4 light wacks the other way n the rest by hand

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Gonna roll the FJ into storage. No time. Building a 460 for my son’s 4x4 n a 351W stroker for something else So the transfer case just became a winter project

Couple of pics of my FJ before going under a tarp

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