Please help. My output shaft slipped out and I believe that the only way to repair this issue is by removing the transfer case. Does anyone have a how to remove the transfer case. I have remove all the bolts that connect the tranny as well as the bolts for both shafts, by the case won't fall? PLEASE HELP.
FJ60 transfer case help (7 Viewers)
- Thread starter fj60sanramon
- Start date
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Good right up here:
https://forum.ih8mud.com/threads/transfer-assembly-with-pictures.487813/
...via IH8MUD app
https://forum.ih8mud.com/threads/transfer-assembly-with-pictures.487813/
...via IH8MUD app
get a copy of the body & chassis manual. Please. There should be a digital version available if you search for it.
The transfer case needs to be disassembled to be removed from the transmission. The back half of the case comes off, the gears and shafts are removed and only then can you access the last bolts that hold the front half of the case onto the back of the transmission.
Did your output shaft really slip out or is it the idler gear shaft? Either way, you probably have to take the thing apart.
The transfer case needs to be disassembled to be removed from the transmission. The back half of the case comes off, the gears and shafts are removed and only then can you access the last bolts that hold the front half of the case onto the back of the transmission.
Did your output shaft really slip out or is it the idler gear shaft? Either way, you probably have to take the thing apart.
The likelihood of dirt entering and contaminating the transfer's innards is high when the back cover gets removed while the transfercase is still bolted to the tranny under the car. But sometimes you gotta do what you gotta do. If you are going to remove the back cover while the transfer is bolted to the tranny under the car (not recommended), clean the transfer case as well as you possibly can... especially the top of it.
Here is a LINK to the manual
Here is a LINK to the manual
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- Thread starter
- #5
The idler gear shaft slipped out...
- Thread starter
- #6
How do I put the idler shaft back in. The screw was loose, causing the shaft to slip.
- Thread starter
- #7
Is there a how to that can show me how to remove the drive shafts and put back the idler shaft? Also, should I know pull the idler shaft completely out?
Thinking on the optimistic side..
The degree of optimism one may reasonably assume is directly related to how far the idler shaft slipped out.. and if the car was driven with it as such.
Lets assume that the car wasn't driven with the idler shaft fully disengaged from the front case idler retainer (inside)... and that it only slipped out a little bit.
The back transfer case rear cover still has to come off to put the idler shaft, with the idler gear and bearings back into position.
Every gasket that is opened up will have to be replaced, along with the 2 idler shaft O'rings.
The degree of optimism one may reasonably assume is directly related to how far the idler shaft slipped out.. and if the car was driven with it as such.
Lets assume that the car wasn't driven with the idler shaft fully disengaged from the front case idler retainer (inside)... and that it only slipped out a little bit.
The back transfer case rear cover still has to come off to put the idler shaft, with the idler gear and bearings back into position.
Every gasket that is opened up will have to be replaced, along with the 2 idler shaft O'rings.
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READ THIS
Leave the idler as it is for now. The rear case has to come off. Don't drive the car. Follow the step by step instructions in the manual carefully. It is not hard to work on the transfer case. Everything is like a big tinker toy set... just a lot heavier.
It is easier to remove the drive shaft if you remove the grease zirc on the slip joint to relieve pressure.
Mark the drive shaft location on the flange so that it will be replaced in exactly the same orientation.
Follow the manual and you will be fine if you are up for it.
- Thread starter
- #10
Thank you! One more question. Can the car be towed to the shop in this condition?
BTW, how far is the idler shaft sticking out?
Picture?
If it is only sticking out about 3/16" of an inch or so, it may be possible to carefully tap it back into place with a plastic hammer. No hard banging. It should tap in easily with the flat cutout on the end aligned where the little retainer stop plate will rest. If it does not. Stop.
If the idler shaft is sticking out more than about 5/16" or so, the O-ring seal on the other end of the shaft may have been lost and there would be no way to just tap it in as the O-ring would bind and not seat correctly. The rear cover would have to come off to reposition everything.
Picture?
If it is only sticking out about 3/16" of an inch or so, it may be possible to carefully tap it back into place with a plastic hammer. No hard banging. It should tap in easily with the flat cutout on the end aligned where the little retainer stop plate will rest. If it does not. Stop.
If the idler shaft is sticking out more than about 5/16" or so, the O-ring seal on the other end of the shaft may have been lost and there would be no way to just tap it in as the O-ring would bind and not seat correctly. The rear cover would have to come off to reposition everything.
and the idler shaft end inside the t-case is going to have to center in the hole on the thrust washer on the backing plate...if that thrust washer has moved during the time that the idler shaft jumped out of position, then if the idler shaft is hitting the thrust washer, it won't seat all the way in...or if the thrust washer has dropped down into the t-case, then it is now loose inside the case...
Tapage
Club 4X4 Panamá
if ain't move by something the thrust washer tent to stick to the flat surface on the t-case ... either way agreed with was posted above, to start with, how much is sticking out ?
