Builds Cruisermatt's FJ62 Build-up (2 Viewers)

[cruisermatt]

Soon
I noticed a grinding gear noise when letting off throttle at speeds higher then 55-60mph or so for maybe the past eight months or so. I initially thought it was the transmission so a few months ago I pulled it and found that bad input bearing. Fixed that, no change. Ok, next thing to do is put new bearings in the transfer case. I didn't when I put it together in 2016 and I had bought it used with unknown mileage AND have run it dry several times (it had a leak from the adapter plate, more on this later), it probably has a bad bearing. There were a few mods I wanted to do as well.

No fun plans on July 4th so transfer case and doubler come out (1 hour to remove, in the rain too):
Also, it had barely any oil in it

I opened it up, was shocked for a few minutes, then did some research then started this thread:
(ominous hint)

Advance Adapters spacer measurement needed

I realize this is probably a shot in the dark, but does anyone have an adapter kit for a GM transmission disassembled that can take a measurement for me? I need the height of this spacer. AA is closed today, just seeing if I can get a jump start instead of waiting till they're open Monday...

forum.ih8mud.com

 

[tmxmotorsports]

Soon
I noticed a grinding gear noise when letting off throttle at speeds higher then 55-60mph or so for maybe the past eight months or so. I initially thought it was the transmission so a few months ago I pulled it and found that bad input bearing. Fixed that, no change. Ok, next thing to do is put new bearings in the transfer case. I didn't when I put it together in 2016 and I had bought it used with unknown mileage AND have run it dry several times (it had a leak from the adapter plate, more on this later), it probably has a bad bearing. There were a few mods I wanted to do as well.

No fun plans on July 4th so transfer case and doubler come out (1 hour to remove, in the rain too):
Also, it had barely any oil in it

View attachment 2025028


I opened it up, was shocked for a few minutes, then did some research then started this thread:
(ominous hint)

Advance Adapters spacer measurement needed

I realize this is probably a shot in the dark, but does anyone have an adapter kit for a GM transmission disassembled that can take a measurement for me? I need the height of this spacer. AA is closed today, just seeing if I can get a jump start instead of waiting till they're open Monday...

forum.ih8mud.com

Lol

 

[NeverGiveUpYota]

I’ve seen the carnage... aren’t you gonna share w/ the rest of mud? I’ll show mine if you show yours.

 

[cruisermatt]

I’ve seen the carnage... aren’t you gonna share w/ the rest of mud? I’ll show mine if you show yours.

I was hoping to build up some suspense

 

[NeverGiveUpYota]

I was hoping to build up some suspense

There’s already plenty!

 

[Mr Cimarron]

My split case is tearing itself apart. I have been changing oil every other oil change and it’s getting darker and darker every time. Gears sound like a Formula 1 car. I’m down for seeing some carnage so I know what to expect at some point. I’m hoping it will last long enough until I go back to 80 series case.

 

[GLTHFJ60]

psssst............guys...........np205 - put a centered rear axle in with a np205 and call it done

 

[cruisermatt]

psssst............guys...........np205 - put a centered rear axle in with a np205 and call it done

Shhh

 

[gbogh]

If that's where this is going, do you go to something like a Tundra rear or go domestic?

 

[GLTHFJ60]

If that's where this is going, do you go to something like a Tundra rear or go domestic?

Tundra rear doesn't make sense when it isn't a toyota purist build. Wheel bolt pattern of that axle can't be made to match 6x5.5 IIRC. Something domestic (ford 9", D44, D60, 14b, whatever) is easy, and wheel bolt patterns can be made to match the (still) toyota front end.

 

[cruisermatt]

If that's where this is going, do you go to something like a Tundra rear or go domestic?

Tundra rear doesn't make sense when it isn't a toyota purist build. Wheel bolt pattern of that axle can't be made to match 6x5.5 IIRC. Something domestic (ford 9", D44, D60, 14b, whatever) is easy, and wheel bolt patterns can be made to match the (still) toyota front end.

I would just center my 80 rear axle, it would be pretty easy. Maybe one day I will go back to single T-case, my perspective has changed a little bit and while dual cases are really cool and it’s fun to have a bunch of options I think the simplicity of a single low geared transfer case along with less shifter mods, gear slop, and in my case better potentially better driveline angles wins out in future builds. My FJ40 rock crawler will have a single T-case. No current plans to make any changes on this truck right now, but I do daydream about a
ZF6-s650 or 6L80e mated to an Atlas with centered rear axle. Just a daydream though.

 

[gbogh]

Tundra rear doesn't make sense when it isn't a toyota purist build. Wheel bolt pattern of that axle can't be made to match 6x5.5 IIRC. Something domestic (ford 9", D44, D60, 14b, whatever) is easy, and wheel bolt patterns can be made to match the (still) toyota front end.

Ahhhh. yes. I forgot the early tundras were 6x5.5 w/ 8in r&p and the 10.5in r&p was 5 lug

 

[cruisermatt]

Anyways back to current situation.

When using any Advance Adapters kit with the splitcase they all have this spacer that goes under the transfer input gear. It’s what’s being pointed at in the picture (not mine) below. I bought my NP203 doubler and adapter setup used and what I believe happened is when the previous transfer case that installed on this adapter was removed from this spacer got taken with it. I would not have ignored it if it was leftover after the T-case was assembled.
When the input gear is installed without this spacer the input gear can sit on the seal and look correct, because you can’t see under it.

When I separated the case halfs, here’s what I found, along with several nice sized metals chunk in the bottom of the case:

 

[cruisermatt]

Anyways, I have a complete other 38mm manual shift T-case so I will rebuild that one instead. However I will be keeping this case complete as I actually think it would still be fine for something like an FJ40 or stock 60 that won’t see really high speeds for extended periods of time. Just needs some welding and the seal area rmachined, should be a fun repair.

 

[cruisermatt]

It should be noted that I’ve put over 25k miles on this transfer case like this. And without oil for extended periods I think four times?
It started making a grinding noise on deceleration at high speeds about eight months ago, and a clunk on takeoff that I noticed getting worse started about the same time. Other then that it was fine, under load, cruising, quiet. I believe under load the input gear wants to thrust towards the rear off the vehicle (where it would hit the PTO gear, spacer and bearing and make full contact with idler gear), a under coast thrust forwards and grind the case, which corresponds with the noises I had and probably explains why this didn’t just completely grenade.

TLDR splitcase is BAMF that can even stand up to my abuse

 

[tmxmotorsports]

I wonder how the nut on the input shaft of the tcase was torqued without the spacer taking up the gap the bearing must of had a serious load on it

 

[GLTHFJ60]

Eventually the nut would bottom out on the shaft's shoulder, or the input gear was being pressed into the case.

 

[cruisermatt]

The nut was bottomed out on the shaft’s threads for sure. The whole case would be locked up from the beginning otherwise.

 

[Mr Cimarron]

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.

 

[BGarcia88FJ62]

Anyways, I have a complete other 38mm manual shift T-case so I will rebuild that one instead. However I will be keeping this case complete as I actually think it would still be fine for something like an FJ40 or stock 60 that won’t see really high speeds for extended periods of time. Just needs some welding and the seal area rmachined, should be a fun repair.

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