FJ60 transfer case removal and rebuild question

[fred]

Hey, gang... I'm in the midst of doing a rebuild on the split T-case on the '82 FJ60 I recently purchased.
Seems pretty straightforward, but some of the "easy stuff" seems to be glossed over. I'm working off the older Haynes, which does seem to cover the t-case rebuild, while the newer haynes completely avoids the topic as "too complicated".

One problem is that I have no idea how the shifter is attached to the shaft that moves the shift fork. I see an arm, a small square intermediate piece between the arm and the shaft, which fits in a notch in the shaft. No idea how it is attached. Can't see the ends, and it's pretty gummed up.

I am assuming that this is where I disconnect this, but maybe not.

Any clues?

No obvious bolt.

Any other tips for doing the t-case rebuild with the tranny still in the vehicle? Or links? My searches have not proved fruitful.

Thanks!

 

[2mbb]

download a copy of the toyota FSM from here: Index of /Cruiser and M416 Manuals

There is a schematic on this post: https://forum.ih8mud.com/60-series-wagons/366524-2-low-trouables.html#post5329300 The orienation of the drawing is that the blue arrow points to the front of the truck and the red arrow points towards the transmission (to the left side of the truck).

It's just a friction fit. Nothing really holds it together except the positioning of the shfit linkage and shfit fork.

 

[fred]

Many thanks!

Very handy those PDF manuals!!
Stick copies on the Kindle, the netbook, and the phone...

Now to figure out if my in-lb torque wrench with the long needle indicator will suffice as the torsion spring scale for measuring shaft pre-load.

Any thoughts on this?

I'm finding that the selection of specialized automotive tools available at autoparts stores is diminishing very rapidly.
Are people just not wrenching on their own cars anymore?

 

[cruiser_guy]

Are people just not wrenching on their own cars anymore?

The manufacturers are making it very hard to work on your vehicle with all the electronics and crap on new vehicles nowadays.

 

[2mbb]

Very handy those PDF manuals!!
Stick copies on the Kindle, the netbook, and the phone...

Now to figure out if my in-lb torque wrench with the long needle indicator will suffice as the torsion spring scale for measuring shaft pre-load.

Any thoughts on this?

I'm finding that the selection of specialized automotive tools available at autoparts stores is diminishing very rapidly.
Are people just not wrenching on their own cars anymore?

I think you will want to invest in a fish scale. When testing the preload you want to measure the force when pulling parallel to the tangent of the stud bolt circle or perpendicular to the radius line drawn from the center to the stud/bolt. I'm not sure you can accomplish this with a torque wrench.

Maybe what's happening with specialty tools is that they are becoming more specilized (each car brand/model needs a specific tool). this makes it difficult for generic auto parts stores to stock all but the most basic or common tools. You can purchase Toyota SST's from here: Welcome to SPX Toyota

Anyway, I would go to a fishing/sporting goods store, not an auto parts store to get a fish scale.

 

[rover24]

2mbb can you elaborate more on the preload. I've read the fsm and just can't get it. From what I gather you would hook the fish scale to output flange bolts and torque the nut on output to spec. I think it's like 8-11 in pounds. Then stake the nut. Not sure where the torque to 94 ft lbs comes in and also the shims.
Sorry for the dumb questions, just can't wrap my head around preload. Even on the pinion nut. Just don't get it!