Hi all, first time poster. I recently bought my first FJ80, a '92 with 275k. As far as I can tell, it's basically been neglected, but not abused, and I've been fixing things as I drive it.
It had a pronounced clunk/shudder when going between drive and reverse or when letting off and reapplying the gas. I've read up on that here and so was checking all the drive line and suspension components and I think I narrowed it down to the drive plates and splines (visible rotational play at the plates, 1/4-turn of play in the front propeller shaft). I replaced the plates, but the splines were pretty worn, so the clunk was only reduced.
Due to time constraints (mostly), I took it to a nearby 4x4 shop to have the front axle rebuilt (birfs, bearings, seals) as the birfs were clicking in turns (especially reverse), and I wanted new splines to help reduce the clunk further. The shop tore the axle down and then had to order parts, so tried backing the truck out of the bay and couldn't get it to move. They claim they engaged the center diff and that the light was on the dash, so let's assume that's correct for the moment. They think the transfer case is bad and that the truck has been operating in front-wheel-drive. One option they suggested was to replace the T-case. Is this the culprit? I don't believe it is, but I'll get to that at the end.
A few more details about my experience driving / getting to know the truck:
- I have been driving around with and without the CDL engaged, depending on conditions
- The clunk goes away when the center diff is locked
- I feel the tires bind up in turns when the diff is locked
The truck is at the shop, so I can't test myself, but it seems to me that if the transfer case wasn't sending power to the rear, the truck would not be able to move without the center diff locked, as all power would be going to whatever has disconnected from the rear axle. Am I correct here?
My suspicion is that the diff lock actuator isn't fully engaging, preventing the rear from getting power and the truck from moving. Are there things I can suggest for them to try?
Thanks,
IronWheel
It had a pronounced clunk/shudder when going between drive and reverse or when letting off and reapplying the gas. I've read up on that here and so was checking all the drive line and suspension components and I think I narrowed it down to the drive plates and splines (visible rotational play at the plates, 1/4-turn of play in the front propeller shaft). I replaced the plates, but the splines were pretty worn, so the clunk was only reduced.
Due to time constraints (mostly), I took it to a nearby 4x4 shop to have the front axle rebuilt (birfs, bearings, seals) as the birfs were clicking in turns (especially reverse), and I wanted new splines to help reduce the clunk further. The shop tore the axle down and then had to order parts, so tried backing the truck out of the bay and couldn't get it to move. They claim they engaged the center diff and that the light was on the dash, so let's assume that's correct for the moment. They think the transfer case is bad and that the truck has been operating in front-wheel-drive. One option they suggested was to replace the T-case. Is this the culprit? I don't believe it is, but I'll get to that at the end.
A few more details about my experience driving / getting to know the truck:
- I have been driving around with and without the CDL engaged, depending on conditions
- The clunk goes away when the center diff is locked
- I feel the tires bind up in turns when the diff is locked
The truck is at the shop, so I can't test myself, but it seems to me that if the transfer case wasn't sending power to the rear, the truck would not be able to move without the center diff locked, as all power would be going to whatever has disconnected from the rear axle. Am I correct here?
My suspicion is that the diff lock actuator isn't fully engaging, preventing the rear from getting power and the truck from moving. Are there things I can suggest for them to try?
Thanks,
IronWheel
