Early one-piece Tcase idler gear installation “how-to”

[orangefj45]

I was contacted by another mud member asking for tech support. He’s working on an H42 and Tcase combo out of a mid 70s FJ40 and had a tough time installing the idler gear assembly.
So here are some pics of how we perform the install.
First, lay out all your parts. ALWAYS!!!!!

Georg @ Valley Hybrids, Cruiser Brothers & Long Range America

 

[orangefj45]

Make sure everything is properly cleaned. For the purposes of this thread, we use some parts for mock up. This is not a final assembly.

 

[orangefj45]

Apply some assembly grease to the side of the washer ( both sides of the spacer ) that makes contact with the inside of the case housing.

 

[orangefj45]

Install the new idler shaft part way into the case, from the rear. You can push it about 1” into the case. Slide the washer ( and spacer where applicable ) onto the shaft. Then pull the shaft back out until it’s flush with the inner edge of the thrust washer.

 

[orangefj45]

Use a socket roughly the same diameter as the idler shaft ( or just slightly smaller ) as a “mock-up” shaft for the other side to hold the front thrust washer in place.

 

[orangefj45]

Slide the bearings snd spacer ( between the bearings ) into the idler gear.

 

[orangefj45]

Lower the gear into the case.

 

[orangefj45]

Slide the new idler shaft into the gear towards the front of the case. Apply a small amount of silicone to the o-ring to help it slip
Into the case and seal the area.
The new idler shaft will push the socket out of the front side of the case.
Georg @ Valley Hybrids, Cruiser Brothers & Long Range America

 

[orangefj45]

Install the retainer tab and bolt. We use a small amount of loctite to keep the bolt where it needs to be.

 

[orangefj45]

Apply a small amount of silicone to the area where the freeze plug needs to be installed; the idler shaft bore at the front of the case. Then install the freeze plug.

 

[orangefj45]

And this part of the repair/reseal/rebuild is completed.
Hope this helps.
Georg @ Valley Hybrids, Cruiser Brothers & Long Range America
Shop 209-475-8808

 

[POPO AGIE]

And this part of the repair/reseal/rebuild is completed.
Hope this helps.
Georg @ Valley Hybrids, Cruiser Brothers & Long Range America
Shop 209-475-8808

I just got home and read your posts and I was on the right path. I put some RTV on the thrust washers to see if that helps to make them stick long enough to get the idler gear in place. I forgot about using a socket for a dummy shaft.

I used a dummy shaft to do the same job on a NP203 transfer case in college.

 

[RWBeringer4x4]

2nd laying out all your parts - Or you can do what I did and find the freeze plug laying on your bench after you’ve already mated the case to the transmission and shoved the whole assembly back into the 40

 

[POPO AGIE]

2nd laying out all your parts - Or you can do what I did and find the freeze plug laying on your bench after you’ve already mated the case to the transmission and shoved the whole assembly back into the 40

I already had the bearings and the spacer in the idler gear. I have a section on my bench with the parts.

I do major inspections on power generation turbines and generators. We have a strict policy of tag and bag for all the parts, then we have a cleaning station were were store the parts in marked bines.

 

[merbesfield]

That was a great write up. Thanks George. You made it so simple even I could follow along