Builds Cruisermatt's FJ62 Build-up (4 Viewers)

[cruisermatt]

That is exactly what I found in my split case when I swapped trans. The oil slinger was gone and melted the seal the rear case. I was able to grind it out and install another seal. I did not put another slinger in.

Were you missing the spacer as well?

 

[cruisermatt]

Judging by the pictures I would think those gears would be fine in a rebuild but the front half of that case is junk.

It’s repairable if you’re crazy enough and have the right equipment. Which I am and do

 

[Mr Cimarron]

Were you missing the spacer as well?

Nope it was there. My issue came after I installed Mark’s gears. The whine was there before and didn’t change after rebuild using the new gears. I went back and measured the spacer and it was the proper length.

 

[White Stripe]

I know of a very good deal on a fj40 crawler if your interested. Probably needs some tweaking, but has a lot of good stuff.

 

[cruisermatt]

I know of a very good deal on a fj40 crawler if your interested. Probably needs some tweaking, but has a lot of good stuff.

Thanks but I'm building my own send it though I may have some interested friends

 

[White Stripe]

Thanks but I'm building my own send it though I may have some interested friends

You can rework it to make it your own. Whatever you want to do of course but it has a awful lot of good parts for the money. Sending PM

 

[cruisermatt]

Decided to try something on the old idler shaft after seeing @Godwin ‘s thread with his falling out. The idler shafts are tough hardened steel but no match for my 1” carbide rougher, even with chipped teeth on it lol

 

[cruisermatt]

No transfer case is safe from Florida Man and his Bridgeport mill

 

[Godwin]

Decided to try something on the old idler shaft after seeing @Godwin ‘s thread with his falling out. The idler shafts are tough hardened steel but no match for my 1” carbide rougher, even with chipped teeth on it lol

View attachment 2025982

View attachment 2025981

My bolt is now loctited.

 

[cruisermatt]

My bolt is now loctited.

How about loctite, double retainer, and safety wire?

 

[Godwin]

How about loctite, double retainer, and safety wire?



View attachment 2026022

I think that will work, if not you have much bigger problems

 

[Mr Cimarron]

hopefully that works for you. Here is how Mark's gears does it. When I snapped the photo just now I realized I never staked the nut. I had always thought Mark's gears were the issue until you have the same issue with the slinger.

 

[GLTHFJ60]

^^ Matt didn't have an issue with the slinger. Matt had an issue with the input gear, and the idler gear slinger was a victim of that issue. Your slinger problem is almost certainly different.

 

[cruisermatt]

^^ Matt didn't have an issue with the slinger. Matt had an issue with the input gear, and the idler gear slinger was a victim of that issue. Your slinger problem is almost certainly different.

Yeah, I don’t know how @Mr Cimarron could have even had an issue if his spacer under the input gear was present

 

[cruisermatt]

Anyways, more mods. Ever since I put the 203 in the rig I had issues with the 7/16-14 (coarse thread) bolts that thread into the aluminum adapter plate coming loose. Attempts to retorque resulted in a few stripped threads, so I just jammed some M12’s in there as a stopgap until I could fix it right.
Obviously being the splitcase there are a few bolts that can’t be accessed without case disassembly.

So, I installed Time-serts in the adapter.
Fresh steel threads will let me torque the bolts to higher values and make threadlocker compound more effective. I may also safety wire some for triple fix.
(Many people don’t understand that threadlockers are anerobic and won’t really be super effective in stripped threads because of tiny air pockets)

I also noticed that I was missing the M12 dowels, that located the transfer front half on the adapter. One of the holes for which isn’t even drilled, thanks Advance Adapters!
This is probably not helping the bolt looseneing either since the transfer case was probably shifting around on the adapter I circled the missing dowel locations, need to make some dowels and get them installed unless someone has the part number for the Toyota dowels in the back of the H55f. I didn’t have any luck. I could buy them on McMaster but I’ll probably just make them so I have them today.

 

[cruisermatt]

Got my spare 38mm case disassembled, cleaned and painted.
Duplicolor Cast aluminum for the win.

IH8cleaning transfer case housings so much. Next aluminum transfer case I do is getting sent to the machine shop to be hot tanked.

 

[tmxmotorsports]

They are a pain to get clean greasy bastards soaks right into the aluminum

 

[cruisermatt]

DIY Mcnamara gear done..

New removable 2wd/4wd linkage made (old one was just welded to shaft)

Old

New

4wd light plugged. I was never going to get around to wiring that.

 

[cruisermatt]

After that I did my Florida Man mod to my new case and idler shaft and got the whole thing put together with a rebuild kit.
And yes I uncharacteristically splurged for some shiny fresh Toyota hardware just for looks

I’m really excepted to drive it with all the crap that was wrong with the other case fixed and fresh bearings.
Just to summarize, (hopefully) fixed issues are:
1.Input gear moving axially and grinding case
2. Loose adapter bolts causing leaks and possible case movement
3. Missing dowels
4. Main case leak
5. Loose front/rear output bearings

 

[tmxmotorsports]

DIY macnamara gear done..

View attachment 2029553

New removable 2wd/4wd linkage made (old one was just welded to shaft)

Old

View attachment 2029556


New

View attachment 2029555View attachment 2029554


4wd light plugged. I was never going to get around to wiring that.


View attachment 2029557

Shifter shaft linkage looks real fimilar