HELP! Transfer Case Removal and Installation (1 Viewer)

[kylenine]

Recently purchased a 1967 fj40 that starts and runs like a champ....but I can't drive it!


PO was driving down the freeway and lost half of the transfer case and the rear driveshaft. The transfer case is sheared in half (see pics) and definitely not useable. Good thing I have an extra one laying around. I have the original straight 6 motor and a 4-speed transmission (which is not stock) it also has a butterfly mount to the frame so it isn't the stock TC mount, but I don't think that will make a difference... I just want to drive!

So my question is this,
I drain the fluid in the tranny
I use a jack to hold the transmission after I take off the TC mount
Then I take off what is left of the TC (use a jack to hold it or can I man handle it out of there?)
Then I put the other TC back on and attach it to the TC mount (after getting proper seals and such)
Then I fill the fluids and hook up my driveshafts, then hook up the E brake and speedometer cables and I'm done?

I'm a little bit of a newbie at this part of mechanics...did I miss anything? Or should I follow those steps and I should be back on the road?

 

[cruiserjunkie]

Ive lifted the transfer up without a Jack its heavy

 

[shelfboy1]

the t case weighs 75 lbs, even my old ass can still bench press them up there.but do it so you are safe good luck

 

[Living in the Past]

I have a early 68 with the same setup except do not have the mount on the back of the transfer case. Looks like a PO cut the crossmember out and used the that instead. Not a good idea if you still have the motor mounts on the bell housing. If the frame flexs it puts extra strain on the motor mounts. If the motor mounts are gone from the bell housing you will need to support the transmission while you remove the rear crossmember that was added or the back end of the engine/transmission will drop down.

 

[inkpot]

Good chance this damage was due to driving down the freeway in 4 wheel drive. There are some minor differences between the 3 speed transmission and transfer case versus the newer 4 speed stuff. They are not perfect replacements without some extra work/parts. If you just do the trasnfer case, I think you need a special input gear that fits the older transmission and the newer transfer. If you are changing both then you need to change some of the bellhousing and clutch stuff. Search for 3speed to 4 speed swaps and you should find lots of good info. John

 

[Living in the Past]

Looking at the pictures on a computer and not my phone I can see you have a adapter between the four speed and transfer case. Probably best to post some pictures of your engine and transmission to see what setup you have. I am running a Toyota 74-80 four speed which bolted direct to the transfer case, no adapter needed. Toyota ran that setup during part of 74 and early 75. All the parts needed for the inside are available new. Only thing different on bolting the two together is the four speed used a different thread so you needed bolts from a four speed since that where the threaded holes are.

 

[RWBeringer4x4]

The transfercase really isn't THAT heavy (about 75lbs as shelfboy said) - but it can be a little cumbersome to lift/align/etc. as one person. A jack can help, but probably not necessary. Plus, based on what's left of your case, I'd say you've got less than 50lbs left to remove...

If you are running a Toyota 4-speed transmission, I'd recommend going with a 4-speed transfercase. They're a bit stronger than the older 3-speeds, and they will mate a lot more nicely. A 3 speed will mate to a 4-speed Toyota trans if you swap out the 4-speed input gear with a 3-speed one.

That said, the adapter plate implies that you might be running a non-toyota transmission. Most trans conversion use the very similar GM top-loaders (SM420 or SM465). It will definitely help to identify what transmission you're running, as this will help the forum determine what you need to do to get your 40 back on the road!

 

[Living in the Past]

If you are running a Toyota 4-speed transmission, I'd recommend going with a 4-speed transfercase. They're a bit stronger than the older 3-speeds, and they will mate a lot more nicely. A 3 speed will mate to a 4-speed Toyota trans if you swap out the 4-speed input gear with a 3-speed one.

The reason people like the three speed transfer case is because it has a lower gearing in low range. The four speed transfer case has wider gears and in general a quieter case. Breaking gears in either case normally isn't a problem unless some else goes wrong inside the case. What is different is how brittle the housing is. Later three speed cases have more gussets and are considered to be stronger than the earlier ones. As for just using the three speed transfer case gear on a Toyota four speed it's not that simple. The tail shafts are shaped differently and have a different spline count. You use all the four speed parts that ride on the tail shaft except for the input gear and bearing. Those are special and need to be purchased.

In this case it's a moot point since he is running a adapter and that will dictate what transfer is needs. Best to pull the transfer case off and count the splines. Ten count for a three speed transfer case and sixteen count for a four speed transfer case.

As for the adapter most SM420 adapters are simple plate with a spud shaft. Does the SM465 use a wider adapter? Still need more pictures. If your running a six cylinder with a four speed that is long as the Toyota four speed than add this adapter and your rear driveline is not going to be that long. Add a lift which will increase the driveling angle that could explain why the transfer blew up on the highway.

 

[73tlcv8]

The sm465 to 3speed TC adapter I had was a plate about 1 inch thick. Can someone ID the adapter shown?

 

[kylenine]

4-Speed Tranny to 3-Speed transfer case?

Recently bought a 1967 fj40 with the stock F motor, a 4-speed transmission, and a (twin stick shifter) 3-speed transfer case (that was broken from PO driving on the road in 4wd). I took the broken transfer case out of the land cruiser yesterday but now is when I have some difficult decisions to make...

The PO installed the four speed tranny to the 67' but with some sort of adapter (see pics) he put the TC from the 3 speed back onto the transmission. I know that 4 speed transfer cases are tough to track down and I ended up with another 3 speed TC from another parts vehicle. Does anyone have an adapter and know the pros and cons to that or a 4speed TC?

Should I just use the 3speed TC that I already have and just install it back to the way it was before with the adapter?
Or should I try hunting down a 4 speed transfer case and installing it?
If I end up with a 4speed TC, can I still use my twin stick transfer case shifters or will I have to swap to a single stick TC shifter?

E pictures show both the transfer case that I have and the broken transfer case with the adapter that I pulled out.

 

[Living in the Past]

https://forum.ih8mud.com/40-55-series-tech/756900-help-transfer-case-removal-installation.html

Instead of starting a new thread for the same problem you started a thread for yesterday just add a new post and keep it altogether.

 

[Rockets2000]

Which 4-spd trans do you have?

 

[kylenine]

Sorry Living In The Past, I am kind of new to this whole "forum" thing...

But I do not know which four speed trans I have, the guy told me it was out of a 76' but it could be out of any year. It is a land cruiser transmission though. I have another land cruiser with a four speed and this one is exactly the same. As far as the adapter, I do not know where it is from. There is no name on it and there is no number of any kind. I don't want to get into switching out the bearings And such, that kind of just complicates things. This adapter is definitely more thick that one inch and I have not been able to identify it...could it be custom made by PO?

 

[kylenine]

Further research (the big letters "GM") shows that this transmission is a SM465 transmission, they look very similar.

Anyways, I am thinking about changing out my rear end now. I have a 205 TC in great condition and would like to put it to use but I don't know it is worth all of that work. I also kind of want to use the transmission to transfer case adapter and just use the 3-speed transfer case that I already have but I don't know if I trust the adapter. Does anyone know what this adapter is?

 

[Poser]

It is a land cruiser transmission though.

No it is not a Land Cruiser transmission.

It is most definitely a GM four speed, and the adapter is most likely an Advance Adapters component.

 

[inkpot]

Looks a lot like the Advanced Adapters setup I had in my 72 years ago. There should be an input stub shaft still in the top of the transfer case and there should also be a big steel sleeve that connects the stub shaft to the output shaft on the NP465. The adapter is a strong product, but the 3 speed transfer case is the weak link. You could put a transfer case saver on it to help some. IIRC, that AA adapter will not fit up to the stronger Toyota 4 speed transfer case. John

 

[kylenine]

Yeah I figured that out Poser, they look very similar but I did more research...

I was thinking that it could be an Advanced Adapter but don't they usually mark their signature on the side of it? I am going to clean it up tomorrow and see if it has some sort of mark but there is none that I can see...is there any other way to tell?

 

[kylenine]

Had a busy week but finally managed to get the adapter off of the transfer case and clean it up.

I ran the code that it had on it and can to figure out that it is an Advanced Adapter. They sell for about $300 on the web. I ordered a 3-Speed gasket and seal kit from eBay so all I need now is some drive shafts that match up (I am hoping I will pull off putting the stock driveshafts from a parts truck that I have)

I got the soft top on and cleaned up and it Looks like I am close to done and getting this thing drivable!