LC100 headers install and tcase regear

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The case is out, not sure yet how I'm gonna manage to get it back in since it almost killed me

I broke the speed sensor, that's going to be annoying to deal with. Haven't even looked up the price yet

Currently stuck on removing the shaft from the part in the top left. Took me a bit to get the snap ring off. It doesn't fit in my press and I can't seem to hammer it through, made me mad enough to stop working on the tcase tonight

So I moved to the headers. They've been soaking in PB blaster every day for a week through several heat cycles. Heated the bolt with a torch and the first one snapped off in the motor

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i may be in over my head 🙃
 
do yall think I can get away with reusing this..?

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They're really expensive unless I order from Japan for $100 which would take like a month.. the break isn't at a sealing point and I don't think it would cause leaking


edit,
I was really confused when I was tearing down my case because this part of the case in the videos that ive watched does not at all look like mine:
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as shown in the photo i posted earlier, this plate is ontop of the coupler instead of below:
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it had me really confused when i first opened it. hoping theres no fitment issues
 
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frawstme said:
I was really confused when I was tearing down my case because this part of the case in the videos that ive watched does not at all look like mine:
Click to expand...

mine actually looks completely different inside too after removing that pain in the ass plate on top. No vicious coupler
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80 series has HF2AV (Viscous Coupler)
100 Series, both JDM and NA market have no VC.

The VC sometimes fails and people remove it. It is also possible to add VC to a 100 series T-case. Also possible to add a Torsen.
 
hoser said:
80 series has HF2AV (Viscous Coupler)
100 Series, both JDM and NA market have no VC.

The VC sometimes fails and people remove it. It is also possible to add VC to a 100 series T-case. Also possible to add a Torsen.
Click to expand...

brother you have so much knowledge about landcruisers, thank you. So these cases are the HF2A not HF2AV ?

i didn't know we could add a torsen, I might have waited to regear if I knew that. I've literally never seen anyone talking about that. In too deep now though
 
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This little trick isn't working for me. I can't keep the base from spinning. I know this metal is frail to impact, I'm guessing I can't stick it in a vice?


Shorter puller did me no good either
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Not sure if it's a matter of strength or a matter of needing a different puller but I can't get it to budge



at 7:15 he spins it right off with absolutly no issue. this is a slightly different tc than mine, but that part looks exactly the same. im not missing something right?
 
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This has been a struggle, definitely not a beginner job.

Every header nut that I have tried won't budge and I'm worried about breaking another one. Not too sure what to do about it, I keep just soaking more with PB blaster while I work on the tcase

I got one shaft out, the one where I was expecting a VC to be. That part is fully disassembled. Took a while to get the big snap ring off.

The other shaft won't budge. It doesn't fit in my press, I can't think of a way to make it work. In the timmytoolman video the guy has a huge press and a specialized plate for it.

The gear clusters I can't break free with my puller set. I'm torn between buying a bearing splitter and tall arbor plates to press them out, or to risk putting the gearset in my vice. The first option won't help me with the big gearset when I get to it though.

Also, there is a very concerning spot on my case where something spinning has caused a gouge in the metal. I'm going to take a picture tonight to share it here to see what you guys think. Hopefully I'm just overthinking it
 
frawstme said:
This has been a struggle, definitely not a beginner job.

Every header nut that I have tried won't budge and I'm worried about breaking another one. Not too sure what to do about it, I keep just soaking more with PB blaster while I work on the tcase

I got one shaft out, the one where I was expecting a VC to be. That part is fully disassembled. Took a while to get the big snap ring off.

The other shaft won't budge. It doesn't fit in my press, I can't think of a way to make it work. In the timmytoolman video the guy has a huge press and a specialized plate for it.

The gear clusters I can't break free with my puller set. I'm torn between buying a bearing splitter and tall arbor plates to press them out, or to risk putting the gearset in my vice. The first option won't help me with the big gearset when I get to it though.

Also, there is a very concerning spot on my case where something spinning has caused a gouge in the metal. I'm going to take a picture tonight to share it here to see what you guys think. Hopefully I'm just overthinking it
Click to expand...

frawstme said:
This has been a struggle, definitely not a beginner job.

Every header nut that I have tried won't budge and I'm worried about breaking another one. Not too sure what to do about it, I keep just soaking more with PB blaster while I work on the tcase

I got one shaft out, the one where I was expecting a VC to be. That part is fully disassembled. Took a while to get the big snap ring off.

The other shaft won't budge. It doesn't fit in my press, I can't think of a way to make it work. In the timmytoolman video the guy has a huge press and a specialized plate for it.

The gear clusters I can't break free with my puller set. I'm torn between buying a bearing splitter and tall arbor plates to press them out, or to risk putting the gearset in my vice. The first option won't help me with the big gearset when I get to it though.

Also, there is a very concerning spot on my case where something spinning has caused a gouge in the metal. I'm going to take a picture tonight to share it here to see what you guys think. Hopefully I'm just overthinking it
Click to expand...
I decided to do my 1st manifold replacement and several times, I started wondering if I could get a mobile repair guy or need a wrecker to get it to a shop. BUT! I finally bought enough swivels and extensions to get it off. I cleaned it and now I'm stuck with which side of the gasket goes against the head. I keep reading different opinions. Also, some manual said to keep the painted tab out. My OEM gasket doesn't have a painted tab. Good thing I have a back up transportation and plenty of time. Anybody have a definitive source on the gasket?
BTW, I had better luck with Kroll spray than with PB.
 
kja1989 said:
I decided to do my 1st manifold replacement and several times, I started wondering if I could get a mobile repair guy or need a wrecker to get it to a shop. BUT! I finally bought enough swivels and extensions to get it off. I cleaned it and now I'm stuck with which side of the gasket goes against the head. I keep reading different opinions. Also, some manual said to keep the painted tab out. My OEM gasket doesn't have a painted tab. Good thing I have a back up transportation and plenty of time. Anybody have a definitive source on the gasket?
BTW, I had better luck with Kroll spray than with PB.
Click to expand...
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this is all I can find

my gaskets do not have any paint marks on them either
 
well I made some progress
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I am stuck on getting the shaft out (upper left corner) and pulling the gear slider support off of the high range. I clipped it a little when my puller slipped, it's hard to get a pic of but here it is:
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Praying that won't be an issue..

There's some weird marring on my case too:
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The second one is particularly bad, the surface has what feels like a cut in the upper left side. Is that an important surface?
 
Also my kit came with this replacement, it looks near identical to the one that I have in my case already. Was this unnecessary? (Obviously I don't have the bearing pressed on yet)
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Will heat help me with this? I'm not sure if using a torch is the best idea or if it would just expand both the shaft and the sleeve.

I spent hours on it and I am making absolutely no progress

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I finally got the main shaft out of the case and everything else is totally torn down. Once I get this off I can start rebuilding
 
Check this out. If you haven't watched his series on how to tear down and rebuild the tcase, you should.
 
I'm interested in seeing how the rhino header fit, I heard there could be fitment issues at least for the LHD version
 
Dirt J said:
Check this out. If you haven't watched his series on how to tear down and rebuild the tcase, you should.
Click to expand...

I did, it just wasn't working for me with my puller. I ended up bringing it into my shop and we used these things
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It came off like butter, thank god

Scotty UZJ100 said:
I'm interested in seeing how the rhino header fit, I heard there could be fitment issues at least for the LHD version
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homie giving me something else to worry about 😆
 
👍🏼 Yes, I invested in a large bearing splitter as part of this project too. Forgot about that.
 
It took a decade but I finally got it separated. Now I'm stuck on something different, having a hard time finding it. I accidentally popped these rings out but I don't know what orientation there's supposed to go back in

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Ran everything through the parts cleaner, got everything organized and assembled two of the clusters. Can't do the third one til I find a picture of the orientation of those rings. Will press the two input shafts tomorrow and cut the shields for the new low range.
 
I notched the web of the shift fork too bc it was just knicking the edge.
 
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