Cruiserdrew
On the way there
Ok-So I took the day off today. Some of you might know that I have a brand new H55f transmission that Cruiserdan delivered to me in Moab. I've been anxious to get on the project, and since I've worked 11 days in a row, I took off today to start on the install.
Today was the day to really get on the transfercase. I have a 1987 donor T-case that will be installed with the H55. First the t-case had to be completely dissassembled for rebuild and I have a pic of the garage carnage after the dissasssembley was complete. The front output can be disassembled with a brass drift, a press is not required. After removing the check ball and the shift fork, it is possible to drive out the output shaft, then remove the snap ring and drive out the output support bearing. Easy stuff.
The really hard part is the rear output shaft. After the check ball is out, the gear cluster and shift fork comes out in your hand. Thats when the fun starts. The bearings are pressed on both ends of the output shaft. The first time through I tried a 2 jaw puller and it broke. Then I went to Harbor Freight to buy a shop press and they were out! So I went to my differential guy's shop and he helped me out big time and pressed off the old output shaft bearings and pressed on the new ones. Those bearings are seriously on there-we were pressing with the whole 50 ton out-put of his press. For me at least, the press was absolutely required. I was actually very suprised at the force it took.
Then back to the front part of the case-I had been dreading re-threading the middle bolt hole you have to plug with the H55f. It looked easy to fawk it up. In reality, though, it was a cinch. I used a 1/4 inch pipe thread tap and just used the existing hole. The threads turned out really clean and I installed a 1/4 NPT plug with blue Locktite. See the pic. Then I installed the oil seals and am ready to mount on the back of the H55.
You can see in some of the pics the oil seal that allows oil to migrate from the transfer to the transmission. Pictured is the new seal in place. You can also see the oiler cup that snaps in place in the collector on the front face of the T-case. There is much more to come, but I thought the pictures might be helpful if anyone else is rebuilding a split transfer case on an FJ60.
Today was the day to really get on the transfercase. I have a 1987 donor T-case that will be installed with the H55. First the t-case had to be completely dissassembled for rebuild and I have a pic of the garage carnage after the dissasssembley was complete. The front output can be disassembled with a brass drift, a press is not required. After removing the check ball and the shift fork, it is possible to drive out the output shaft, then remove the snap ring and drive out the output support bearing. Easy stuff.
The really hard part is the rear output shaft. After the check ball is out, the gear cluster and shift fork comes out in your hand. Thats when the fun starts. The bearings are pressed on both ends of the output shaft. The first time through I tried a 2 jaw puller and it broke. Then I went to Harbor Freight to buy a shop press and they were out! So I went to my differential guy's shop and he helped me out big time and pressed off the old output shaft bearings and pressed on the new ones. Those bearings are seriously on there-we were pressing with the whole 50 ton out-put of his press. For me at least, the press was absolutely required. I was actually very suprised at the force it took.
Then back to the front part of the case-I had been dreading re-threading the middle bolt hole you have to plug with the H55f. It looked easy to fawk it up. In reality, though, it was a cinch. I used a 1/4 inch pipe thread tap and just used the existing hole. The threads turned out really clean and I installed a 1/4 NPT plug with blue Locktite. See the pic. Then I installed the oil seals and am ready to mount on the back of the H55.
You can see in some of the pics the oil seal that allows oil to migrate from the transfer to the transmission. Pictured is the new seal in place. You can also see the oiler cup that snaps in place in the collector on the front face of the T-case. There is much more to come, but I thought the pictures might be helpful if anyone else is rebuilding a split transfer case on an FJ60.