Porch Transfer Case Rebuild (Lotso Pics)

[POPO AGIE]

When I rebuilt the 78 4 speed and transfer case it was not supposed to have the PTO gear but it did. I just put it back in. With out it I would have needed spacer to replace it with.

When assembling you will need to make a pulling device like shown in the manual to keep the transmission output shaft up against the thrust washer or it will end up rotation and the anti rotation pin will not say in the slot on the washer and lock up the whole train. I just stacked up the parts and used the nut to pull everything up and kept the washer and pin in alignment.

 

[cruiseroutfit]

I do not have a PTO winch or anything else, but would it make sense to install that gear while I'm in there just to have it incase I someday acquire a PTO winch? Is there a spacer needed if I do not install the PTO gear? What about a welsh plug to seal up the back of the idler shaft? And thoughts on the worm gear for the spedo cable, this new t-case does not have one, should I get a new one or just reuse the one currently on the truck?

Thanks!

Yes, I'd install the gear if a PTO might ever happen. There is still a spacer behind that as shown in the diagrams above

As for the plug, part# 90330-27010, our part# TCSHFT27010

The speedo drive gear (and driven gears too) are generally re-used unless damaged or severely worn out.

 

[Living in the Past]

Yes, the rear bearing dimension is different.

There is even a way to go from a 3spd J30 transmission to the 4spd 1pc t-case using the TCG3621260021 and a 30mmx75mm bearing. That gear has the 10 spline for the J30 but the 31 teeth needed for the 4spd 1pc t-case.

Thank you Kurt. Thought that was reason the two cases were different.

I have researched the late one piece transfer cases and found using the three speed idler gear and low range it will have three low ranging in a four speed. Looking around those two gears may still be available. Expensive but available.

 

[cruiseroutfit]

Thank you Kurt. Thought that was reason the two cases were different.

I have researched the late one piece transfer cases and found using the three speed idler gear and low range it will have three low ranging in a four speed. Looking around those two gears may still be available. Expensive but available.

Holler if we can help. We stock all of the input, idler, high speed and low speed gears for the 3sd, transition and 4spd case fwiw. Front output, rear output and idler shafts too!