FJ60 clutch or transmission issue?

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This morning I paid close attention to the pedal play and found this much play in the master cylinder rod. The pedal measures the correct distance from the floor but there is still that much play in the master.

I also tested the clutch for slippage and it passed.

I realize this needs to be repaired but I'm wondering if it is the cause of the awful groan in 4th? Should I bother with replacing the master and slave cylinder before I drop the transmission?

 
What year is your FJ60? That will determine whether or not you have a clutch fork with return spring or not. I'm thinking you have an 1981-1984 which in that case it would be normal to have play there.

But yes don't bother replacing them (yet). You've got something going on lol. Drop the transmission :)
 
Oh. Your FJ60 is probably 5 speed ready then. If you have a one piece cross member, non DC front drive shaft, and "spacer" transmission. You're good to go.

Post a picture of the underside of your truck just so we can confirm. Something that has the transmission cross member in view or the front driveshaft/ clutch fork. A few ways that we can tell.
 
ZgKzdxs.jpg


this the picture you need?

My truck and my wallet might not agree on what will and won't fit. :)
 
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A new H55F 5 speed transmission will bolt right into your car. Piece of cake. No drive line modification necessary. If you decide to go that route, the front plate of the transfer will need a little modification to plug an open bolt hole that is created with the 5 speed installation. Also a little plastic oiler thingy will need to be purchased and snapped in place on the transmission side of the transfer front plate.... and you'll need new shift lever that fits that tranny.... and don't forget the new shift knob!

(Beno can set you up)
 
Output Shaft said:
A new H55F 5 speed transmission will bolt right into your car. Piece of cake. No drive line modification necessary. If you decide to go that route, the front plate of the transfer will need a little modification to plug an open bolt hole that is created with the 5 speed installation. Also a little plastic oiler thingy will need to be purchased and snapped in place on the transmission side of the transfer front plate.... and you'll need new shift lever that fits that tranny.... and don't forget the new shift knob!

(Beno can set you up)
Click to expand...

Going to resist the temptation. This rig stays a 4 speed . I enjoy the slow pace.
 
It may not end up being a temptation, but a wise choice.
Transmission repair can get expensive fast, mostly due to labor costs.
Also many parts for the 4 speed are no longer available.

A new 5 speed can be purchased for around $2300. A full rebuild of a burned up 4 speed can cost over $1500 if you have shop do it. And you end up with some good parts and a lot of not so good parts in the end.

Maybe price out what the costs would be to buy and have a new 5 speed installed vs. getting your burned up gearbox patched. The difference is not that much. It doesn't matter to me.. I just don't see the value in trying to super-glue an old transmission together that has a quarter of a million miles on it that sounds like crap. When it sounds like that... everything inside it is worn. That racket was caused by inadequate lubrication in the past. And when there is inadequate lubrication.... everything wears out together...fast.
 
All good info and I appreciate your insight. It appears that I can buy a 4speed from a cruiser friend for a few hundred dollars and keep it on the road.

Rebuild the clutch and install a used transmission is the current plan.
 
Watching the outcome here, have a similar issue. According to kline's chart my noise is none of the above. Interested to see your problem resolved. Ironically, I too have a 7/85 build, so maybe there was a bad batch of bearings or something lol.
 
Output Shaft said:
It may not end up being a temptation, but a wise choice.
Transmission repair can get expensive fast, mostly due to labor costs.
Also many parts for the 4 speed are no longer available.

A new 5 speed can be purchased for around $2300. A full rebuild of a burned up 4 speed can cost over $1500 if you have shop do it. And you end up with some good parts and a lot of not so good parts in the end.

Maybe price out what the costs would be to buy and have a new 5 speed installed vs. getting your burned up gearbox patched. The difference is not that much. It doesn't matter to me.. I just don't see the value in trying to super-glue an old transmission together that has a quarter of a million miles on it that sounds like crap. When it sounds like that... everything inside it is worn. That racket was caused by inadequate lubrication in the past. And when there is inadequate lubrication.... everything wears out together...fast.
Click to expand...


$2089.00 for an H55F these days.

:cheers:
 
OGBeno said:
$2089.00 for an H55F these days.

:cheers:
Click to expand...

It's still February? :D

I'm still pushing for a 5 speed. Although I really doubt your bearings in your transmission could be making that much noise and there would be no metal flakes in the oil. My H42 makes less noise and had/ has lots of flakes in it.
 
One of the major causes of metal particles ending up in the transmission oil and on the magnet (which causes increased wear inside the whole transmission) is grinding the transmission into reverse.

h55f-05-reverse-idler-jpg.943686
 
dirtEJohnson said:
Watching the outcome here, have a similar issue. According to kline's chart my noise is none of the above. Interested to see your problem resolved. Ironically, I too have a 7/85 build, so maybe there was a bad batch of bearings or something lol.
Click to expand...

Yeah, a bad batch of bearings that lasted 30 years with questionable maintenance habits.... Hardly.
 
Just an update to this fun journey.

Georg set me up with a working 4 speed and a seal kit for the tcase and tranny. This weekend I pulled everything out.

Here are my findings.

Clutch: Normal wear but better than expected. Going to replace with new everything "while I'm in here"

Flywheel: Getting resurfaced.

Old transmission: With the transfer case still attached I could put it in 4th gear and hear the growl from something. Took off the transfer case and tested again and the growl was coming from the tranny.

Tcase: new seals and gaskets installed. It's a little tricky getting everything back together.

New Transmission: New seals installed. Tested in through all the gears and it checked out.

Bolted the tcase up to the new transmission and it shifts and goes through the gears nicely.

Install of master cylinder, slave cylinder, and everything else awaits me. My wife is out of town this weekend so I hope to get this cleaned up and ready for a test drive.

Tcase split apart:
vy8y7SA.jpg


I could strangle the engineer that hid this bolt behind the input gear!

XjLwONl.jpg


Shout out to orangefj45 for walking me through a few items.

Have a great week!
 
Resurfaced flywheel installed and the new slave cylinder. It is so nice working with clean parts. Makes me dread going back into the engine bay...

Then I ran out of time and left my mess until next time.
 
Recruited a friend to help muscle the transmission back in last night.

Everything went well and we had the transmission ready to bolt in when I realized that the clutch fork and throw out bearing weren't installed. In my rush I forgot it. No wonder sliding in the transmission was so easy the first time. Back out came the transmission and with the fork and throw out bearing in the bell housing we wrestled everything back in place. The sound of the everything going clunk when re-installed is pretty darn satisfying.

With the new clutch parts bled out in was time to test it out. Unfortunately I couldn't take it around the block because the front end it torn apart waiting it's turn for an overhaul. So we ran it on jack stands and it all seems to be working together nicely.

I took some really poor video of it running but it's probably only exciting to me.

So, I guess this will turn into my rehab/build thread. Onto the power steering and suspension later this week. Hoping to get out on Sunday to give everything a good test.

Thanks for the all the help on the forum. I feel a little bit of, "if he can do it why can't I do it?" every time I log in!
 
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