Vae Victus
Posting more than I know
I will be documenting my H42 tranny rebuild here for the good of the masses since I cannot seem to find a complete one anywhere.
Telling an H41 and H42 apart: https://forum.ih8mud.com/40-55-series-tech/652966-can-you-tell-h42-h41-visually.html
I will do my best to get this right, and with the help of the Mud community, I'm sure we will get close.
Caveat emptor: I am not a mechanic. I did however sleep in a Holiday Inn Express last night (yea, that's about as qualified as I am to do this).
I am using the FSM for a 1975 FJ40, and one from the 1980 FJ40 (Chassis and Body) from TrollHole's thread, (Tip: the '80 manual is more descriptive and asker to understand than the '75 manual where it relates to the 4 speed transmission - get both) as well as the notoriously ill informed Haynes manual. I will also be using sheer will and determination to get this done.
TrollHole's FSM Free Download thread: https://forum.ih8mud.com/sale-parts/610994-40-50-60-80-series-fsm-hell-price.html
I purchased my rebuild kit from TPI4x4.com. It came with a full set of blue paper gaskets, Koyo bearings, seals, needle bearings, crush washers. I'll detail the kit here in the near future.
I like to bag and tag all pars in zip lock bags, with the part name written in sharpie on the bag.
Step 1: Removal of the Transmission
This is widely covered in other places, therefore I'm not going deep here. Basically, you must remove the drive shafts, and remove the seat and tranny hump from inside, and several other parts to get the transmission and transfer case out. Can be done as a single unit or together. See my thread (in sig line) if you need details on this. It points to my sources of how I figured this out.
Step 2: Separation of Tranny and Tcase
Again, covered elsewhere. See my thread for how I did it.
Here is the transmission pre-tear down
H42 Transmission - Hump Side
H42 Transmission - No Cover Plate
Note the absence of the "Power Take Off" Cover present in older H42 models. My transmission must have been replaced at some point with a newer model that does not have this plate. Most documentation shows this plate and suggests your remove it as one of the first steps in the teardown. If you have it, take it off as it may make viewing and accessing the inside easier. Plus, you need to replace the gasket.
Front, "Input" side from Clutch/Engine
Back - "Output" side to Transfer Case
Step 3: Shift lever removal
I had trouble with this. I did not have or make a tool to do this task, so I tried a vice grip to push down on the shift lever and to turn it clockwise. Did not work. This may come back to bite me, but I just removed the whole unit as one by removing the cover plate.
Shift Cover Plate Removed
Shift Lever and Cover Plate
Step 4: Top Cover Plate Removal
Simply removed the bolts and tapped the cover to loosen it with a dead blow hammer. Pried it off the two locator pins that sit at the 11 oclock and 5 oclock positions on the case where the cover fits on. At first I thought these were sheared bolts, but looking and seeing that they were chamfered on the ends, I figured they were supposed to be there.
Top Cover Plate Removed - Locating Pins shown
Locating pins detail
Telling an H41 and H42 apart: https://forum.ih8mud.com/40-55-series-tech/652966-can-you-tell-h42-h41-visually.html
I will do my best to get this right, and with the help of the Mud community, I'm sure we will get close.
Caveat emptor: I am not a mechanic. I did however sleep in a Holiday Inn Express last night (yea, that's about as qualified as I am to do this).
I am using the FSM for a 1975 FJ40, and one from the 1980 FJ40 (Chassis and Body) from TrollHole's thread, (Tip: the '80 manual is more descriptive and asker to understand than the '75 manual where it relates to the 4 speed transmission - get both) as well as the notoriously ill informed Haynes manual. I will also be using sheer will and determination to get this done.
TrollHole's FSM Free Download thread: https://forum.ih8mud.com/sale-parts/610994-40-50-60-80-series-fsm-hell-price.html
I purchased my rebuild kit from TPI4x4.com. It came with a full set of blue paper gaskets, Koyo bearings, seals, needle bearings, crush washers. I'll detail the kit here in the near future.
I like to bag and tag all pars in zip lock bags, with the part name written in sharpie on the bag.
Step 1: Removal of the Transmission
This is widely covered in other places, therefore I'm not going deep here. Basically, you must remove the drive shafts, and remove the seat and tranny hump from inside, and several other parts to get the transmission and transfer case out. Can be done as a single unit or together. See my thread (in sig line) if you need details on this. It points to my sources of how I figured this out.
Step 2: Separation of Tranny and Tcase
Again, covered elsewhere. See my thread for how I did it.
Here is the transmission pre-tear down
H42 Transmission - Hump Side
H42 Transmission - No Cover Plate
Note the absence of the "Power Take Off" Cover present in older H42 models. My transmission must have been replaced at some point with a newer model that does not have this plate. Most documentation shows this plate and suggests your remove it as one of the first steps in the teardown. If you have it, take it off as it may make viewing and accessing the inside easier. Plus, you need to replace the gasket.
Front, "Input" side from Clutch/Engine
Back - "Output" side to Transfer Case
Step 3: Shift lever removal
I had trouble with this. I did not have or make a tool to do this task, so I tried a vice grip to push down on the shift lever and to turn it clockwise. Did not work. This may come back to bite me, but I just removed the whole unit as one by removing the cover plate.
Shift Cover Plate Removed
Shift Lever and Cover Plate
Step 4: Top Cover Plate Removal
Simply removed the bolts and tapped the cover to loosen it with a dead blow hammer. Pried it off the two locator pins that sit at the 11 oclock and 5 oclock positions on the case where the cover fits on. At first I thought these were sheared bolts, but looking and seeing that they were chamfered on the ends, I figured they were supposed to be there.
Top Cover Plate Removed - Locating Pins shown
Locating pins detail
Last edited: