@POPO AGIE thanks for posting that picture. That is the sleeve that's in your post #57, picture titled "removed the rear bearing cover"? My sleeve has a wear groove in it. I was just reading the FSM and the output shaft nut is supposed to be torqued to 100 lb*ft, but my nut wasn't near that tight, in fact I could wiggle it back and forth within the groove on the shaft where you stake the nut. I'm 99.99% sure my T case had never been touched before, so this is very odd.
Rebuild of 4-Speed and Transfer Case (2 Viewers)
- Thread starter POPO AGIE
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POPO AGIE
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- Thread starter
- #62
Did the shim and washer also show wear and was the nut staked? I used a 1/2" drive impact to get the nut off set at full power and the compresser had not built up the regulated pressure yet, and it took a bit but I don't know what the torque really was.
The rear output seal leaked and soaked the brake shoes and I replaced the seal and the shoes from under the truck and I think I used a torque wrench back then which had to be in the early to mid 80s . The rear main seal leaked the entire time I had the 2F engine and should have made the dealership replace it when I took it in for the first oil change.
I know the history my my FJ40 because I bought it with 30 miles from the dealership in Cheyenne, Wyoming.
POPO AGIE
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- #64
Have the material analyzed and have new ones made. A good machine shop should have a gun that will tell them what it is and if it is not something exautic they should be able to machine new parts.
We do it all the time on turbine outages when the Customer does not want to pay the OEM price go to a third party so I can't give them the material spec for a third party
We do it all the time on turbine outages when the Customer does not want to pay the OEM price go to a third party so I can't give them the material spec for a third party
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POPO AGIE
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- Thread starter
- #65
I had a bearing puller set delivered, but every jaw was too large to fit in the holes in the case to get jaws behind the bearing race.
So I ran to NAPA with the Toyota repair manual to show them what I was trying to do. I also took the smallest arm in the kit to show that it has to be smaller to fit in the hole in the case. Well, I came to the conclusion that I would have to modify the jaws to a profile that would go through the holes and get behind the bearings.
COMPARISON OF THE THE JAWS BEFORE AND AFTER GRINDING THE PROFILE TO FIT IN THE CASE HOLES
PROFILE 2
So I ran to NAPA with the Toyota repair manual to show them what I was trying to do. I also took the smallest arm in the kit to show that it has to be smaller to fit in the hole in the case. Well, I came to the conclusion that I would have to modify the jaws to a profile that would go through the holes and get behind the bearings.
COMPARISON OF THE THE JAWS BEFORE AND AFTER GRINDING THE PROFILE TO FIT IN THE CASE HOLES
PROFILE 2
@POPO AGIE the sleeve I was referring to previously was the one in your picture above.
Yes!! Mine has a groove worn on both sides. Had to get a replacement to the sum of $122. Glad yours is ok.
Good job Popo! You have been a busy man lately. Thanks for sharing.
POPO AGIE
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- Thread starter
- #73
It helps to have a seasonal job and I am transferring from an affiliate of GE to GE Steam Power so I have been off for a few weeks. We had a very busy fall and spring. I work 1650 hours before overtime and I have ~400 left and if we have a good fall I will have premium time before January.
From Cheyenne. Passed through your parts going to Jackson Hole elk hunting many times. Wolves showed up and it all changed. I still apply for the bison tag. Someday....
POPO AGIE
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- #75
My Nephew lives in Cheyenne and is the head wrestling coach at the new high school and teaches PE.
I bought my FJ in Cheyenne when there was a Toytoa dealership there in the late 70s.
I grew up in Green River, then moved to PA for a few years until the property taxes put me in Iraq and told the Wife if I got out alive I had to move back to the mountains.
If your nephews name is TJ. He lives across the street. You and your FJ40 have a long history.
POPO AGIE
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- #77
That is so cool. I use to take TJ and his Sister skiing in the FJ40 in Teton Village and Togwotee on the west side of the Tetons. TJ and I went camping with my Son when he was 3, up on the Union Pass road, wound up not at the Horse Shoe lake and it snowed. I did not have the top on because the last time it was too hot during highway driving.
I will bet TJ likes your FJ45.
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When TJ saw my FJ45. He told me about a relative with a Landcruiser that took him to some cool places. He mentioned the Diesel engine swap too. I read your posts and just realized you bought it new. I have lived across the street from TJ for over 8 years. I am lucky to have good neighbors. When I see TJ I will tell him about you too. Wyoming is a big state but it is still like a small town. I hope it doesn’t change.
merbesfield
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Small world. Huge state and you live across from his nephew.
merbesfield
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Did the jaws work? Worried about how thin they had to be to get in there.
