Rebuild of 4-Speed and Transfer Case

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merbesfield said:
I can't believe the idler gear fell right out after giving you fits.
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It is hard to hold inside the case with my big hands and it has to be aligned perfectly to clear the bosses for the hi lo shifter shaft. Gravity was all it needed and when I when to rolled the case over it was hanging out like the PTO gear did. Now I hope it goes back just as easy.
 
Did more cleaning today that I could get with the wire wheel and some things that had soaked overnight like the front drive shift shaft until the battery was dead on the grinder.

Put more parts in the solvent and put some back that needed more soak time.

Started assembling the front drive cone.
Mounted the bearing on the front out put shaft
BEARING MOUNTED ON THE FRONT DRIVE SHAFT.webp


Installed the shaft bearing and the snap ring in the front drive cone
SEATED THE BEARING AND THE SNAP RING IN THE FRONT DRIVE CONE.webp


Installed the new seal with a light film of Permatex Ultra Black

NEW SEAL INSTALLED ON THE THE FRONT DRIVE CONE.webp


Installed a new bearing race in the front drive cone

NEW RACE INSTALLED IN THE FRONT DRIVE CONE.webp


Packed the new needle bearings and installed in the idler gear with the old spacer between them.

New idler shaft with a new O-Ring

IDLER GEAR WITH THE NEW BEARINGS OLD SPACER NEW SHAFT AND NEW ORING.webp
 
I keep dreaming about it I have to keep working on it.

I am waiting for the Shop that removed the shifting fork shaft to call me back to see if they have a large hot tank. 100K miles of the rear main seal leaking and the dirt is not coming off very well and there are to many ribs in the aluminum to get into with a wire brush on a grinder.
 
POPO AGIE said:
I keep dreaming about it I have to keep working on it.

I am waiting for the Shop that removed the shifting fork shaft to call me back to see if they have a large hot tank. 100K miles of the rear main seal leaking and the dirt is not coming off very well and there are to many ribs in the aluminum to get into with a wire brush on a grinder.
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A hot tank or a Vapor blasting set up. Good luck.
 
merbesfield said:
A hot tank or a Vapor blasting set up. Good luck.
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Small town and not sure what is available. I hope that the shop I went to is able to help out they are very easy to work with.
 
Did more assembly today

Assembled the front drive shifter with new copper washers, replaced the O-Rings on the shaft and the housing. Installed the detent ball and spring, and the shifting fork.



ASSEMBLED THE FRONT DRIVE SHIFTER.webp


Used new copper
USED NEW COPPER WASHERS AND SHIFT BOOT WITH NEW ORINGS.webp
New washers and used Permatex ultra black on the threads of the plugs.

Installed new needle bearings after packing with grease
NEW NEEDLE BEARING INSTALLED IN THE OUTPUT SHAFT.webp


Mounted the High Speed Gear, space washer and bearing
BEARING HIGH SPEED GEAR, WASHER, AND BEARING MOUNTED ON THE OUTPUT SHFT.webp



And still cleaning the exterior parts.
 
The amount of dirt on the cases I am going to have to dredg the solvent tank soon.
 
More cleaning today:

Cleaned up the Speedo housing and installed a new seal with Permatex Ultra black
SPEEDOMETER HOUSING CLEANED AND NEW SEAL.webp


HI LO cover with the seal replaced for the shift fork


NEW SEAL FOR THE HI LO SHIFT FORK.webp



Finally got the Transfer Case cleaned

TRANSFER CASE CLEAN.webp
 
Last night I just could not stay out of the barn so I replaced the seal on the input side of the transfer case



NEW SEAL INSTALLED IN THE INPUT SIDE OF THE TRANSFER CASE.webp



Installed the second new race for the output shaft today
INSTALLED THE SECOND NEW RACE IN THE TRASFER CASE.webp


The idler gear went right into the case but have not figured out how to keep the thrust washers in place to get the gear lined up to install the shaft an bearings. Any suggestions would be appreciated.

THRUST WASHERS AND THE IDLER GEAR.webp


Still cleaning up the last of the parts and the parking brake backing plate is the last part soaking.
 
Great thread @POPO AGIE , I'll be doing the same starting this week. What did you use for solvent and on the grinder?

I spent a few summers working in Dubois, not far from you (at least in Wyoming miles). Great country out there
 
Goldbug said:
Great thread @POPO AGIE , I'll be doing the same starting this week. What did you use for solvent and on the grinder?

I spent a few summers working in Dubois, not far from you (at least in Wyoming miles). Great country out there
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I have a small parts washer but did the grinder/wire brush dry.

Yes Dubois is about 90 miles from my house and not far from the Union Pass road that I have taken the Land Cruiser into a couple of time. It was a lot of technical driving and you needed to enjoy the scenery once you got where you were going.
 
orangefj45 said:
I can post pics of the idler gear/shaft assembly installation if that helps.

Georg @ Valley Hybrids, Cruiser Brothers & Long Range America
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That would be appreciated. There is once issue where the split case is a better design.
 
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