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Gears with all new seals, bearings, shift fork and collar for the 4WD shifter. There are lots of good threads on rebuilding the tcase so no more detail is necessary.
One area that gave me great trouble is in the backlash adjustment of the transmission. This is step 26 and 31 on pages AT-135 to AT-138 of the A440 FSM. My belief after carefully studying the cutaway view is that the new aftermarket gasket (between the steel parking brake housing and the auto case) is a bit thinner than the original. I made a new gasket that was 28 thou thick and that brought the adjustment in step 26 to the minimum end of the clearance., 12 thou. For step 31 the clearance was 4 thou. Not being able to find the proper Toyota shim I elected to grind down a 1.5mm shim by 10 thou. Use a lathe to make a holder. Epoxy the shim into the holder. gently tap the holder in the 3 jaw chuck until a dial runs perfectly true on the face of it. Then slowly grind it by about 1/2 thou at a time until the material is removed. Then heat the holder to soften the epoxy and it falls out. This seems to have worked. Never mind the cuts in the holder, that was a failed attempt at clamping it. Any bit of pressure from the clamps distorted the shim therefore epoxy was used.
Transmission and Transfer Case waiting for the valve body and pan.
Valve Body rebuilt. Unfortunately most of the springs that measured under length are not available so I just cleaned and reassembled it. All the check valve seats showed wear but were in good shape. There are 2 parts of the FSM that are not accurate.
Step 6d on page AT-118 says to install 5 bolts however it should say 6 bolts because there is one in the mid of the cover that needs to be installed during this step.
Step 13 on page AT-123 doesn't list the bolt lengths properly. The 25 should be longer maybe 35 and the lowest of the 29.5 should be 25.
One thing that almost ruined the day was that one of the bolts almost stripped because the stainless plate wasn't lined up perfectly. I had to disassemble, tap and die the hole and bolt, clean it out and then loosen all the bolts a little, slide the SS plate so all bolt holes lined up then start all the bolts carefully then torque everything.
One area that gave me great trouble is in the backlash adjustment of the transmission. This is step 26 and 31 on pages AT-135 to AT-138 of the A440 FSM. My belief after carefully studying the cutaway view is that the new aftermarket gasket (between the steel parking brake housing and the auto case) is a bit thinner than the original. I made a new gasket that was 28 thou thick and that brought the adjustment in step 26 to the minimum end of the clearance., 12 thou. For step 31 the clearance was 4 thou. Not being able to find the proper Toyota shim I elected to grind down a 1.5mm shim by 10 thou. Use a lathe to make a holder. Epoxy the shim into the holder. gently tap the holder in the 3 jaw chuck until a dial runs perfectly true on the face of it. Then slowly grind it by about 1/2 thou at a time until the material is removed. Then heat the holder to soften the epoxy and it falls out. This seems to have worked. Never mind the cuts in the holder, that was a failed attempt at clamping it. Any bit of pressure from the clamps distorted the shim therefore epoxy was used.
Transmission and Transfer Case waiting for the valve body and pan.
Valve Body rebuilt. Unfortunately most of the springs that measured under length are not available so I just cleaned and reassembled it. All the check valve seats showed wear but were in good shape. There are 2 parts of the FSM that are not accurate.
Step 6d on page AT-118 says to install 5 bolts however it should say 6 bolts because there is one in the mid of the cover that needs to be installed during this step.
Step 13 on page AT-123 doesn't list the bolt lengths properly. The 25 should be longer maybe 35 and the lowest of the 29.5 should be 25.
One thing that almost ruined the day was that one of the bolts almost stripped because the stainless plate wasn't lined up perfectly. I had to disassemble, tap and die the hole and bolt, clean it out and then loosen all the bolts a little, slide the SS plate so all bolt holes lined up then start all the bolts carefully then torque everything.