Early one-piece Tcase idler gear installation “how-to” (1 Viewer)

This site may earn a commission from merchant affiliate
links, including eBay, Amazon, Skimlinks, and others.

orangefj45

Supporting Vendor
Joined
Mar 14, 2003
Threads
1,160
Messages
18,407
Location
norcal
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

43C6AE83-0E34-47B3-8067-0CCFA0AD94AA.jpeg
 
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.

4201F9C7-4A29-444A-9C3D-7227BF1822E4.jpeg
 
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.

C88C82B2-30A0-4C1F-A43E-5B4B6F5EE422.jpeg
 
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.

BDB0D7AA-35AD-45E5-92D7-230EC1C29C89.jpeg
 
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.

AE1CD06B-ED07-4DDB-B082-17A48D06FF40.jpeg
 
Slide the bearings snd spacer ( between the bearings ) into the idler gear.

8EF771C5-8D18-43E4-BE54-DE3C09FF109F.jpeg
 
Lower the gear into the case.

57168765-8CFA-4BDA-854D-640FA79769C2.jpeg
 
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

50D154B8-5DD9-447A-A659-3F33002FDF57.jpeg
 
Install the retainer tab and bolt. We use a small amount of loctite to keep the bolt where it needs to be.

EB19B635-F226-4CBC-94DF-C5C5B27E846F.jpeg


F5AF8E24-A014-4345-8F1B-CA2A397F6F8A.jpeg
 
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.

3269E65B-7126-4B9E-8C18-3BE52AEFCE90.jpeg


498AF31A-F6AA-4DBE-BFB1-AA8B5A5A9BD5.jpeg
 
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.
 
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 😡
 
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.
 

Users who are viewing this thread

Back
Top Bottom