PTO removal

[debkev1010]

I'm trying to remove a PTO from my parts FJ40 ('71) to my project FJ40 ('72). I've removed the 5 bolts that hold the PTO to the tranny and have disconnected the e-brake, odometer cable, electrical connections, PTO shifter linkage, front and rear driveshafts. When I first removed the 5 bolts the PTO separated from the tranny about 1/4 of an inch. However, I'm not able to separate it any further. I've tried inserting a ball joint separator into the opening to see if I could pry it off, but had no luck. Should the PTO be in a specific alignment in order to slide it off? Should I use a jack to push the PTO weight off the input shaft and then slide it towards the rear of the vehicle?

Thanks for the help,
Kevin

 

[crushr]

Pics would help. It sounds like you are talking about something other than the factory PTO that mounts to the lower portion of the transfer case. Is this a rear mount PTO? Ramsey? Year/type of truck? Stock drivetrain?

 

[flaminbandit]

there is 6 bolts assuming its a toyota or pow auto unit your prolly missing the very top bolt

 

[andrewfarmer]

Sounds like he's talking about removing the transfer case??

 

[cruiser_guy]

Kevin, the PTO is held on with 6 bolts to the SIDE of the transfer case. It will come off easily. If you are removing the transfer case you need to FIRST remove the PTO gearbox to access 2 bolts which are INSIDE the transfer case (in addition to the 3 long ones accessible from the outside) BEFORE you start prying and prodding. There is also a large nut at the end of the tranny output shaft that must be removed before the transfer case can be removed, it's hidden behind the sheet metal cover at the back of the transfer case.

Mare sure you know what you are doing or you'll have a pile of scrap aluminum!

 

[debkev1010]

Hey guys, thanks for the input and the education. What I thought was the PTO is actually the transfer case. I need to move the transfer case (with PTO attached) to the other vehicle. I have the 5 bolts out that connect the transfer case to the transmission. I have removed the sheet metal cap (6 bolts) to expose the output shaft (I think). There's a nut on the end of the shaft. On one of the six sides of the nut there's a square bump. Is this a square peg that goes through the nut to the output shaft as a locking mechanism? Or do I just have a weird looking nut? If this is a peg, any tips on removing it?

Thanks again,
Kevin

 

[wesintl]

It's probably staked or has a staked washer.

 

[debkev1010]

What does that mean? Can I just start torquing on the nut or do I need to remove the stake and then start torquing?

 

[Pin_Head]

If you are removing the transfer case you need to FIRST remove the PTO gearbox to access 2 bolts which are INSIDE the transfer case (in addition to the 3 long ones accessible from the outside) BEFORE you start prying and prodding. !

As mentioned above, you have to remove the PTO unit from the side of the transfer case FIRST before you can remove the 2 bolts that are inside the transfer case.

 

[cruiser_guy]

I need to move the transfer case (with PTO attached) to the other vehicle.

This CANNOT be done! The PTO unit MUST come off to remove the transfer case. DO NOT attempt to remove the transfer case WITH the PTO attached or you WILL HAVE SCRAP ALUMINUM!

There's a nut on the end of the shaft. On one of the six sides of the nut there's a square bump. Is this a square peg that goes through the nut to the output shaft as a locking mechanism? Or do I just have a weird looking nut? If this is a peg, any tips on removing it?

Thanks again,
Kevin

The nut on the end of the shaft had two different methods of securing it depending on when it was made. Either a cotter pin if the nut is a castellated nut (looks a little like a rook in a chess set) or it is a staked nut (looks like a normal nut but with a smooth area around the top which has one side is pushed in over a relatively small area, 1/8" or so). You need to determine which one you have. We cannot do that for you without a picture. If it is a castlatted nut then remove the cotter pin, if it is a staked nut, CAREFULLY drive a pointed punch under the flattened area BEFORE removal.

 

[vtcruiser60]

Depending how far along you are in removing the pto, I just want you to know that I have a spare PTO on my shelf that is for sale.

Just saying.....

 

[debkev1010]

I'll take some pictures tonight after work and upload them. Thanks again for everyone's interest. This site is exactly what I need.

 

[debkev1010]

Ok, here are the pictures of the transfer case. I drew an arrow pointing to the square bump on the side of the nut. I've looked at other posts about transfer case stake nuts and this doesn't look like any of those. I bought a 27mm impact socket today, but I'm not sure it will fit over the nut with this bump. I may have to grind it down with a dremel tool in order to get the socket over the nut. Thanks for your help.

Kevin

 

[wesintl]

just use a screw driver to bend it out flat so you can get a socket on that nut.

 

[debkev1010]

Hey, you were right...used a screw driver and flattened the piece out. I put a socket on the nut with a 1/2 inch impact wrench and it didn't seem to budge; however, it's about 10 PM and I don't think the neighbors care for the sound of an impact wrench and an air compressor. I'll try again tomorrow.

 

[cruiser_guy]

I don't recall seeing a star washer type securing device on the tranny output shaft before. The nut should come off with your impact wrench.

If you're lucky the case will slide off relatively easy but I doubt you'll be so lucky. You may have to fashion a puller of some sort.

 

[wesintl]

I've always found a breaker bar with a pipe extension works better than an impact wrench. more leverage.

 

[debkev1010]

Finally!!!!!!! I want to take this time to thank all the FJ40 gurus out there, my parents, my 1st grade teacher Mrs. Sparkman, glory halelujah!!!!!

Thanks, guys for your input. I put the impact wrench to it and my eyes got big when I saw the nut starting to move. I then had my cake and ate it too, because I was able to pull the transfer case off without using a puller. Now to move it to the '72.