Removing FJ60 transmission/transfer case - tips?

[Tennessee80]

Inspiring stuff guys…!

 

[Godwin]

This is the after photo once I had the transmission/t-case out. Using the floor jack under the rear wheel I elevated that corner of the truck high enough to roll out the transmission. If you're only replacing a clutch there's no need to go to this effort as there's plenty of room under the truck to move the transmission clear of the clutch and bell housing. I'm replacing the transmission so needed to pull it all the way out.

 

[cps432]

Pulled it again today. Alone.

Here’s a close up of the mount bolted to the jack.

You’ll need to wedge some wooden blocks under the back side of the transmission so the transfer case doesn’t pull so heavy on the back side.

I used to have a plywood platform that bolted to the jack in the four corners. This allowed me to position the jack about 6” further forward than the factory metal plate allows. Pushing the mount forward and bolting it to the plywood helps balance the weight of the transfer case. I will be making a new one before I install this thing again. I makes things much easier.

I also didn’t drain it this time and I most definitely should have. It’s way heavier and unwieldy with oil in it.

 

[garfieldthecat]

Pulled it again today. Alone. View attachment 3178745Here’s a close up of the mount bolted to the jack.View attachment 3178746View attachment 3178747You’ll need to wedge some wooden blocks under the back side of the transmission so the transfer case doesn’t pull so heavy on the back side. View attachment 3178748I used to have a plywood platform that bolted to the jack in the four corners. This allowed me to position the jack about 6” further forward than the factory metal plate allows. Pushing the mount forward and bolting it to the plywood helps balance the weight of the transfer case. I will be making a new one before I install this thing again. I makes things much easier.

I also didn’t drain it this time and I most definitely should have. It’s way heavier and unwieldy with oil in it.

Hi @cps432 , can you please post photos of your wood platform once you make it to get an idea of what bolt holes you make use of or align with on the HF jack in addition to the transmission mount bolts--how far forward they are in relation to the jack platform. I will be dropping and pulling my transmission/transfer case in the next month or two for a T-case rebuild and would like to make reinstallation as safe as possible. Thank you.

 

[4runner2FJ60]

So you bolt the trans mount to the jack after you remove the cross-member? Can someone explain the best way to do that, use another jack I assume to hold trans while removing cross-member?

 

[garfieldthecat]

A chunk of 2x2 or 2x4 wood that you jam between the flywheel and bell housing. This piece of wood will prevent the flywheel from turning as you loosen and later retorque the flywheel bolts. Flywheel teeth will bite into the wood as the flywheel is turned and jam the wood a little deeper against the bell housing. Too loosen just reverse the rotation and the wood will drop free. Use blue loctite on the flywheel bolts and tighten to spec.

Hi @Godwin do the pressure plate-to-flywheel bolts need the Blue Loctite 242 as well or only the flywheel-to-crank shaft bolts? Thanks for any guidance you can provide.

 

[OSS]

So you bolt the trans mount to the jack after you remove the cross-member? Can someone explain the best way to do that, use another jack I assume to hold trans while removing cross-member?

Yes. Support the transmission with the bottle jack then remove the mount and bolt it to a plywood square on the transmission jack.

 

[OSS]

You’ll probably want to replace rhe transmission mount, so you’ll have two to work with.

 

[cps432]

I put a jack stand under the transfer case as far back and away from the transmission as possible. The OEM bottle jack works perfect for this. You don’t need to lift it. Just let it touch so it doesn’t fall.

Make your plate like the one @OSS showed. I leave the mount on the transmission. Remove the cross support member from under the transmission. Move the transmission jack into place and bolt the mounts to the jack plate. Don’t forget to shim the back of the transmission to keep it all stable. It will have a tendency to want to tilt backwards and to the side where the transfercase hangs off. Once the sucker is solid you can remove the jack stand or bottle jack. Then carefully pull the jack straight back and it should slide right out.

 

[CenTXFJ60]

So you bolt the trans mount to the jack after you remove the cross-member? Can someone explain the best way to do that, use another jack I assume to hold trans while removing cross-member?

Lots of good feedback on this. I use two ratchet straps (one may work) around the frame and under the rear output flange

 

[garfieldthecat]

@CenTXFJ60 do you use the blue loctite on the flywheel bolts? Or some other threadlocker? If so, should it be applied to the crankshaft-to-flywheel bolts as well as the pressureplate to flywheel bolts? Thanks for any help on this question. Curious to know what others do on these bolts and if it helps. Thank you

 

[CenTXFJ60]

@CenTXFJ60 do you use the blue loctite on the flywheel bolts? Or some other threadlocker? If so, should it be applied to the crankshaft-to-flywheel bolts as well as the pressureplate to flywheel bolts? Thanks for any help on this question. Curious to know what others do on these bolts and if it helps. Thank you

Yes sir. I use blue (or red if that’s all that’s available) on the flywheel and pressure plate bolts.

 

[cruisermatt]

This is the after photo once I had the transmission/t-case out. Using the floor jack under the rear wheel I elevated that corner of the truck high enough to roll out the transmission. If you're only replacing a clutch there's no need to go to this effort as there's plenty of room under the truck to move the transmission clear of the clutch and bell housing. I'm replacing the transmission so needed to pull it all the way out.

View attachment 3178209

This is giving me flashbacks to 2020 swapping bellhousings in the campsite in Colorado @NookShneer @The Eradicator @CenTXFJ60

 

[garfieldthecat]

Yes sir. I use blue (or red if that’s all that’s available) on the flywheel and pressure plate bolts.

Excellent, thank you. I have never done this job before and want to get it right with the advise of others who have been down this path before (some even several or many times before, I'm sure). Thank you.

 

[CenTXFJ60]

This is giving me flashbacks to 2020 swapping bellhousings in the campsite in Colorado @NookShneer @The Eradicator @CenTXFJ60

That was epic Matt. Still legendary move which is discussed around the campfires

 

[CenTXFJ60]

Excellent, thank you. I have never done this job before and want to get it right with the advise of others who have been down this path before (some even several or many times before, I'm sure). Thank you.

Good on you for tackling this job.

 

[Godwin]

Hi @Godwin do the pressure plate-to-flywheel bolts need the Blue Loctite 242 as well or only the flywheel-to-crank shaft bolts? Thanks for any guidance you can provide.

I only loctite the flywheel bolts and install the pressure plate bolts dry.

 

[John McVicker]

Not saying this is the ‘right’ way…or even a good way. But here‘s a few pics of how I did mine, alone and in a dirt driveway. It might give you some ideas. Used the engine hoist to lift it all into a pick up & took it to my friends shop where we rebuilt the T Case & refreshed the Transmission. ‘86 fj60.

Used 2 straps

Use a good quality Transmission jack

Working in the dirt…not fun

SAS3 attendee Jerry Fie @ his shop

Keep an eye on your straps and keep them tight. No flimsy HF straps

 

[garfieldthecat]

I only loctite the flywheel bolts and install the pressure plate bolts dry.

Thank you @Godwin appreciate your assistance.

 

[NookShneer]

This is giving me flashbacks to 2020 swapping bellhousings in the campsite in Colorado @NookShneer @The Eradicator @CenTXFJ60

The best time to remove your drivetrain is when beer and an audience is around.