Greetings from Japan: Preparing for my first T-case overhaul on my 250k-mile FZJ80

[CrabCake]

You'll do just fine! With all of your forethought and watching the right vids & readings, it's clear that you'll be more than prepared for this.

I met Georg last week at Cruise Moab and thanked him for his video series with Timmy...invaluable for when I did mine at home. He said that it took 18 hours that day to film a 4 part series of 1 hour each and really appreciated my thanks...happy that he knew of at least one person that benefitted from his efforts!

One note, there are a few tricky clips in there that Georg highlights...you may need to buy or alter your spring clip tools to fit just right. Be patient with these and it's really not that hard.

Oh yeah, fantastic rig and ownership history you have!

 

[lc80fzj]

You'll do just fine! With all of your forethought and watching the right vids & readings, it's clear that you'll be more than prepared for this.

I met Georg last week at Cruise Moab and thanked him for his video series with Timmy...invaluable for when I did mine at home. He said that it took 18 hours that day to film a 4 part series of 1 hour each and really appreciated my thanks...happy that he knew of at least one person that benefitted from his efforts!

One note, there are a few tricky clips in there that Georg highlights...you may need to buy or alter your spring clip tools to fit just right. Be patient with these and it's really not that hard.

Oh yeah, fantastic rig and ownership history you have!

You were lucky to meet George! He’s a legend to me. I’ve studied his videos and gathered the exact tools he uses for the T-case teardown. While I couldn't replicate his custom stand (the one his son made) just yet, I'm planning to build my own using 2x4 lumber.

 

[CrabCake]

Yeah, it was great to have a conversation with Georg! He seems very chill, just like in the videos...good people!

For the jig, it would be nice on the bench, but totally not required for the job. I like your jack jig...that should be very handy, especially when reinstalling.

I was lucky enough to have the PO of mine take care of the Marlin Crawler low range gear (where you need to clearance the case). I went in there to do the 10% underdrive gear and part time kit. One note, if you are doing the PT kit, pay attention to the shims needed for the floating bearing race that gets it's preload from shims...most likely you'll need to adjust thickness. If you are not doing the PT kit and just the gears, most likely all will stay the same for the floating differential bearing race shim/s.

 

[lc80fzj]

Yeah, it was great to have a conversation with Georg! He seems very chill, just like in the videos...good people!

For the jig, it would be nice on the bench, but totally not required for the job. I like your jack jig...that should be very handy, especially when reinstalling.

I was lucky enough to have the PO of mine take care of the Marlin Crawler low range gear (where you need to clearance the case). I went in there to do the 10% underdrive gear and part time kit. One note, if you are doing the PT kit, pay attention to the shims needed for the floating bearing race that gets it's preload from shims...most likely you'll need to adjust thickness. If you are not doing the PT kit and just the gears, most likely all will stay the same for the floating differential bearing race shim/s.

Thanks! I'm glad you like my floor jack adapter. I’m really hoping it does the job as expected.
As for my project, I’ll be replacing the input gear, idler gear, and high-range gear. This setup is designed to give me a 10% reduction in high range and a 5% reduction in low range.
Regarding the shims for the idler and output gears that you mentioned, I’m expecting to be able to reuse the existing ones as they are.

 

[lc80fzj]

TC is out.
Started yesterday. Those two front bolts were a nightmare to remove, but I finally got it.