H42 Transmission, Tcase, eBrake Rebuild in a '76 FJ40` (1 Viewer)

vtgbeemer · Sep 29, 2013

Success!!! Jim C mentioned applying heat and I didn't see if you did or not but heat from a propane torch, map torch or in some cases just a heat gun can really help. On the flip side putting bearings in the freezer can aid reassembly.

Vae Victus · Sep 30, 2013

vtgbeemer said:
Success!!! Jim C mentioned applying heat and I didn't see if you did or not but heat from a propane torch, map torch or in some cases just a heat gun can really help. On the flip side putting bearings in the freezer can aid reassembly.

No, once I braced the rear, it pulled pretty easily. I was lucky. The hooks just barely grabbed.

Vae Victus · Oct 3, 2013

Ok pulled the output shaft and gears, counter shaft, and am ready to drive out the reverse idler shaft. How do I remove the key for the shaft?

Output shaft and gears

Reverse Idler Shaft

Instructions say drive idler shaft out

But how to remove this key?

FJ40Jim · Oct 4, 2013

When the shaft is driven out, the key will fall out.

But there is usually no need to remove the reverse or reverse shift fork. These parts have no wear issues.
Wash out the case, dry the case, lube the reverse gear and begin reassembly.

Vae Victus · Oct 4, 2013

FJ40Jim said:
When the shaft is driven out, the key will fall out.

But there is usually no need to remove the reverse or reverse shift fork. These parts have no wear issues.
Wash out the case, dry the case, lube the reverse gear and begin reassembly.

Yes, I read that, but I was uncomfortable with that. I'm in there, it looks easy to clean up, shouldn't I get the rust off the shaft and just go ahead and touch everything?

I'm bad about listening to good advice sometimes (hence the existence of this thread, several folks said "Why the hell are you rebuilding an H42?").

(Thanks for suffering through this thread by the way).

John Smith · Oct 4, 2013

Vae Victus said:
Yes, I read that, but I was uncomfortable with that. I'm in there, it looks easy to clean up, shouldn't I get the rust off the shaft and just go ahead and touch everything?

I'm bad about listening to good advice sometimes (hence the existence of this thread, several folks said "Why the hell are you rebuilding an H42?").

(Thanks for suffering through this thread by the way).

Listen to Jim. I have also never messed with removing reverse on any I have worked on. Nice work removing the output shaft bearing. :beer:

Vae Victus · Oct 4, 2013

John Smith said:
Listen to Jim. I have also never messed with removing reverse on any I have worked on. Nice work removing the output shaft bearing.

Ok. Good timing. Thanks guys. Will press on.

Vae Victus · Oct 4, 2013

Removed the gears from the output shaft today. Took my time to get familiar with how this thing works.

Vae Victus · Oct 4, 2013

12. Started cleaning the case. What a pain. Advice herein was to just leave the reverse idler gear in place, but I may remove it and use electrolysis to clean the case.

Vae Victus · Oct 10, 2013

12. Continued. Against all advice I removed the reverse idler shaft and gear. I cleaned the case via electrolysis and am ready to paint it.

Dirty

Not dirty

Vae Victus · Oct 10, 2013

When measuring the thrust clearances between first second and third gears, how should the shaft and gears be sitting?

If I hold the shaft vertically, the gap is too tight based on the FSM. If I lay it horizontally, the gaps appear to be too large, even holding the gears tight on the shaft.

Rookie. Help.

John Smith · Oct 11, 2013

Vae Victus said:
When measuring the thrust clearances between first second and third gears, how should the shaft and gears be sitting?

If I hold the shaft vertically, the gap is too tight based on the FSM. If I lay it horizontally, the gaps appear to be too large, even holding the gears tight on the shaft.

Rookie. Help.

I performed the tests horizontally, and failed them all. I was *just* out of spec on all of them. I figured the tranny shifted fine when I took it apart; so I put it back together and it still shifts fine years later, despite failing those tests. YMMV, but that is my experience.

Vae Victus · Oct 11, 2013

John Smith said:
I performed the tests horizontally, and failed them all. I was *just* out of spec on all of them. I figured the tranny shifted fine when I took it apart; so I put it back together and it still shifts fine years later, despite failing those tests. YMMV, but that is my experience.

Too tight or too loose?

FJ40Jim · Oct 11, 2013

I check it horizontal, and they are always too loose from the factory. In fact, it seems all the selective fit snapring and shims are the thinnest (loosest) available. Apparently Aisin just throws trannies together at the factory, knowing that the design is good enough that the tranny will function acceptably even if it is slightly loose. My experience has been that an H42 will shift great when put together with all new bearings & syncros, and all selective fits at the bottom edge of acceptable.

Vae Victus · Oct 11, 2013

FJ40Jim said:
all selective fits at the bottom edge of acceptable.

^^^^ what does that mean? Can't tell if an auto correct typo or I just don't understand.

Splangy · Oct 11, 2013

He's referring to the snap rings and other selectable sized parts to adjust play.

Vae Victus · Oct 12, 2013

Splangy said:
He's referring to the snap rings and other selectable sized parts to adjust play.

Got it. ReRead it and makes sense. In other words, get the snap rings that tighten it up a bit, then don't worry about it.

Vae Victus · Oct 12, 2013

So I scuffed the brass bushing inside the reverse idle gear while pounding out the idler shaft (I know, I know, everyone said don't remove it). Doesn't appear to be a big deal.

Anyone disagree? It is soft brass, and although a deep scuff, I don't think it will hurt the integrity or the travel of the gear on the shaft once I buff it a bit.

FJ40Jim · Oct 13, 2013

[STRIKE]Ha, ha! Told ya so![/STRIKE];p

Shouldn't matter much, since 99% of the time reverse is just sitting there, not spinning.

Vae Victus · Oct 13, 2013

FJ40Jim said:
Ha, ha! Told ya so!;p Shouldn't matter much, since 99% of the time reverse is just sitting there, not spinning.

Ouch, talk about kicking a guy when he's down!

At least I'm still progressing:

This was after rinsing off the acid etch. Looks whiter with the flash.