HZJ75 in-vehicle transfer rebuild

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H

HZJ75 FARMER

Joined
Mar 17, 2024
Threads
16
Messages
154
Location
South Australia
I have a H55F in a HZJ75 and would like to do a transfer box rebuild, due to worn input gear splines, loose output shafts, and leaking seals.

I don't have a hoist or pit, so complete removal is difficult, and at this stage I'm not wanting to rebuild the transmission.

Is it possible to dismantle and rebuild the transfer while still mounted in the vehicle?

If possible, is it advisable?

Have any if you done it in a HZJ75?

Thanks.
 
It's not so tricky, on a 60 at least. But by worn input splines, I guess you mean worn splines on the transmission output shaft? If you're 'fixing' that with a longer transfer input gear, then fine. But to replace that shaft is definitely a transmission out job.
 
Eurasiaoverland said:
It's not so tricky, on a 60 at least. But by worn input splines, I guess you mean worn splines on the transmission output shaft? If you're 'fixing' that with a longer transfer input gear, then fine. But to replace that shaft is definitely a transmission out job.
Click to expand...

Yes that's correct, worn splines on the input gear and worn splines on the transmission output shaft. How much of each, I don't really know, it's still assembled. But a modified long spline input gear from Terrain Tamer should do the trick.
 
Gear oil and aussies- tee hee. Years and years ago, mate and I pulled the gearbox/xfer out of an old 61 series patrol. Mate had the bright idea of filling the boxes with gear oil before bolting it all back onto the bell housing. The patrol was on ramps and of course that means we're on our backs under it. Well.... turns out that on the old patrol the gear oil will come out the back of the xfer case (when tilted to get it up) - fortunately (for me) he was on the receiving end and got a nice gear oil shampoo. It took a lot of soap + time for that 'perfume' to dissipate - don't think it helped his love life one iota :)

cheers,
george.
 
I’ve rebuilt mine before from underneath, and also resealed it again when I replaced my h55f.

It’s much easier to rebuild it when it’s off the vehicle and on the ground.

That said, it’s not that bad of a job and comes off piece by piece. The one thing to make it much easier is during reassembly if you can get another set of hands holding things up. Especially when it’s covered in gasket maker.
The other time is when you are trying to line up the high/low shifter fork. It’s pretty easy to get that in the wrong position

Other than that, it’s not a hard job. I will say, if you need to do anything else, clutch/rear main, h55f work, I’d do it all now and not have to reseal that tcase twice.
 
george_tlc said:
Gear oil and aussies- tee hee. Years and years ago, mate and I pulled the gearbox/xfer out of an old 61 series patrol. Mate had the bright idea of filling the boxes with gear oil before bolting it all back onto the bell housing. The patrol was on ramps and of course that means we're on our backs under it. Well.... turns out that on the old patrol the gear oil will come out the back of the xfer case (when tilted to get it up) - fortunately (for me) he was on the receiving end and got a nice gear oil shampoo. It took a lot of soap + time for that 'perfume' to dissipate - don't think it helped his love life one iota :)

cheers,
george.
Click to expand...
The simple answer then is that he was clearly doing it wrong.... :cheers:
 
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Can anyone tell me how to get the housing off the end of the mainshaft?

Do I have to drop the transmission crossmember and lower the trans on a jack, to get below the pipe crossmember behind the transfer?

Or what?
 
One tip for anyone reading this in the future. When you pull the main rear cover off, make sure the idler shaft and gears stay behind. Mine came with the rear cover and then I had a pile of gears all jumbled inside the rear cover that was difficult to get off the top shaft.

Would I do it in-situ again? On this exact vehicle and in this exact situation, probably yes. If I had a hoist, probably no. If I needed to do further work, probably no. Which pretty much echoes others advice at the start.
 
Wow, those are the worst splines I've ever seen.

Mega kilometres on the clock? Tow vehicle? Poor maintenance?
 
Eurasiaoverland said:
Wow, those are the worst splines I've ever seen.

Mega kilometres on the clock? Tow vehicle? Poor maintenance?
Click to expand...

I would say probably all three!

I bought the vehicle recently, no history at all, for pretty much wrecking price. Then decided to make it usable instead of wrecking. Hence not rebuilding the transmission at the same time due to it not being expected to do many kilometres for the rest if its life. But with splines so loose I was surprised it was still driving, it needed something done to it.
 
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