Rebuild of 4-Speed and Transfer Case

[POPO AGIE]

Removed the Reverse Idler Shaft and gear

After checking the kit for a gasket I removed the shift tower for cleaning.

Cleaned the Front Bearing Cover

 

[POPO AGIE]

Cleaned the rear Bearing Cover and Adapter plate

 

[POPO AGIE]

Cleaned the top cover

Bearings in the transmission Kit

Gaskets and seals in the transmission kit

 

[POPO AGIE]

Removed the snap ring on the input shaft bearing

Jaw puller used to remove the input shaft bearing from the shaft

Input shaft bearing removed

Synchronizer ring #1 Sub assembly first gear and thrust washer removed from the output shaft

Snap ring retaining the retaining the Clutch Hub #2 and synchronizer

 

[POPO AGIE]

Snap ring removed

Inner race removed from the counter shaft

 

[POPO AGIE]

Was out cleaning parts and got the output shaft completely unloaded by rapping the end of the shaft on a 2x4 and got the needle bearing 2nd gear, bushing, 3rd gear and the clutch hub to slide off. There is a small detent ball in the shaft that prevents the bushing from rotating inside the gear.

Cleaned the output splines and was apparent that after 100K miles there was wear where it engages the input gear of the transfer case.

Output shaft spline wear

Unloaded Output shaft

 

[fjc-man]

Have you decided to reuse or replace the output shaft? How worn are the splines on the gear that rides on that spot?

 

[POPO AGIE]

I am not doing this to put back into my FJ40 and merbesfield is paying for the parts and it is up to him and then we will ship it to him for his 71. I have to look at the gear again, but I don't think it is worn.

I am going to put an H55F and the split transfer case in my truck behind a Cummins R2.8.

 

[POPO AGIE]

The Input gear looks good.

 

[POPO AGIE]

Replaced the seal on the front bearing cover and did some more cleaning of the gear box.
Then did some masking of transmission parts before painting.

Painted the rear cover/adapter plate

Painted the front bearing cover

Painted the shift tower

Painted the gear box

 

[POPO AGIE]

New Parts arrived by UPS from Cruiser Brothers in Sacramento, CA.

1 input shaft​

1 Main or output shaft​

1 TC input gear​

Cleaned and stoned the gasket areas on the gear box, front bearing cover, rear cover/adapter plate.

Installed the reverse Idler shaft and gear with grease in the bushing and the shaft bores

Reverse Idler shaft seated and anti rotation tab in the case

Shifter arm engaged in the reverse idler gear

Installed the inner race on the output end of the counter shaft set the counter shaft in the case

Mounted a new bearing on the Input shaft that had a new snap ring installed on the bearing

 

[POPO AGIE]

Cleaned the anti-rust coating from the output shaft.

Reused the anti rotation pin from the old output shaft and will start loading the shaft from this end so the pin does not get away.

 

[mrboatman]

Nice work

 

[POPO AGIE]

Nice work

Thank You.
I am really enjoying this. I work on turbines and generators, but don't use my tools anymore so this is fun. I get to stand around and point and fly from my computer.

 

[POPO AGIE]

Missed a photo yesterday.
New Inner race installed on the counter shaft

Snap ring installed on the input shaft bearing

Clutch hub keys and springs

 

[POPO AGIE]

Clutch hub synchros

Gear mounted with new needle bearing

Anti rotation ball in place

Bushing installed and indexed on the anti rotation ball

 

[merbesfield]

Cleaned the anti-rust coating from the output shaft.
View attachment 2748705

Reused the anti rotation pin from the old output shaft and will start loading the shaft from this end so the pin does not get away.

View attachment 2748716

Beautiful piece

 

[POPO AGIE]

Just called Toyota in Lander, WY to see if the parts have arrived that were ordered last week. The large snap ring for the clutch hub came in and the needle bearings for the main shafts come together. The two smaller snap rings for the counter shaft should arrive tomorrow.

 

[POPO AGIE]

Got back from Lander, Wyoming with the large snap ring and the 17 rollers for the two shafts.

Clutch Hub snap ring installed

Synchronizer ring 1assembly

New needle bearing installed and packed with grease for first gear

Installed First gear

Installed the anti rotation pin for the thrust washer

 

[POPO AGIE]

Installed the thrust washer with assembly grease and is indexed with the anti rotation pin. Used assembly grease that is tacky, so that it would not fall out of place while putting the shaft assembly in the box.

Main shaft assembly in the case and the washer did not slip off of the pin.

The inner synchro ring in place before installing the input shaft before the input shaft. Used tacky, assembly grease to hold in place while installing the two shafts.

New needle bearings installed in the input shaft with assembly grease