FJ60 PS Gearbox Leak

[JGM]

Did some research and have not found a similar thread, so I thought I would ask out loud.

I have an FJ60 PS GB on my 4Runner. It was bought from a junker and rebuilt by MAF. Everything looked good with it. For the last few months with some hard wheeling (I run 35's and an ARB up front), it has worked flawlessly.

Unfortunately, yesterday, after a day of wheeling I noticed a lot of groaning from the system. Hopped out to look and there was PS fluid everywhere. I identified the lead coming from the top of the box where the center bolt comes through.

With some playing around, I figured out that when I turn my wheels, some of the time (not all), the nut on that center stud turns as well, resulting in the nut getting totally loose over time, and the fluid was pouring from there.

I am not familiar (yet) with this gearbox, and I am not sure what parts could be missing or how it should be working. Can anyone send me or scan in the FSM on these parts? The schematics at SOR were too vague. All I have is a nut on the stud -- should there be a washer or gasket of somekind? Should the whole thing turn as I turn my wheels? Did something come off over time or did MAF screw up the re-build?

In the meantime, I am torquing that down, but it works loose, and then I re-top the ATF.

Ideas? Thanks folks!

 

[JGM]

OK - I poked and prodded a little more and it looks like the seal under the nut (MAF part 44257A, SOR part 099-19k) was destroyed. Not sure how, but it looks like the nut may have been torqued too hard, eventually resulting in the seal being torn apart?

I think I am getting closer, but I am still not sure of how (per FSM) it should be properly re-assembled. Any help will be greatly appreciated.

Thanks again in advance!

 

[lovetoski]

Not sure that this helps a lot...but here goes...the "nut + stud" are to adj pre-load in the gearbox. The nut is a locknut, the stud is turned/adjusted with a flat screwdriver. Sounds to me like the nut wasn't tightend down enough, came loose, allowing the shaft to become loose, wobble, wear the seal, etc.

 

[JGM]

That may be. If anyone can help me understand exactly how these few pieces fit together, I would be in good shape.

Does anyone have the factory service manual for service on the parts?

Thanks!

 

[sschaefer3]

FSM, you would need to find someone with an FJ-60 or 62. Hmmm, I wonder who it is that you know that has a 60 or 62?

 

[sk8salomon]

Have you replaced the high pressure PS hose? Mine cracked in 3 places this weekend. Had a hard time finding one. Local parts stores had nothing in stock & Toyota said that part was discontinued. Had to take the old hose to a fab shop and braze old fittings on a standard hose.

 

[JGM]

Thanks for the help, Steve. It is much clearer what the whole problem looks like now.

sk8salomon - the hose is fine and there is no leak from it. It is obvious that the fluid is pouring out the preload bolt. The guys at Specter suspect the o-ring under the cover is bad or was not installed correctly. I am going to start there.

 

[60wag]

There is supposed to be a special washer under the locknut. The washer has a seal molded into it. You might try replacing the washer thingy before tearing the box apart.

 

[JGM]

Thanks, guys. I took my issue to a reliable Toy mechanic today and he solidly believes the problem lies much lower in the box, and that it probably was not remanufactured to the utmost.

I have asked MAF to step up and send me a swap-out, since they did the remanufacture about 6 mos ago. Looks like they will do it as soon as they find out if they have one to swap.