Replacing My Transmission what else should I do?

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Apr 30, 2007
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Cody, Wyoming
In all my years of tinkering on vehicles I have never replaced a transmission or clutch. I have done the search but have not found and good write up’s on replacing a H42 with another H42. I’m starting this thread so I can do it right and quickly. I’m on a pretty tight budget so I’m not able to go to a 5 speed at this time.

The reason for the replacement is that my transmission sounds like a rock tumbler all the time except for when it's in 4th gear. I have a good used transmission in hand. What other parts and tools should I get before I get started?

Thanks
-Wyo
 
First make sure that the spare H42 is from before 10/85. It should NOT have the 4" extension on the back end. This was started about 10/85 to make the drive train the correct length for the H55f, but they never sold those in the US.
You will want to change the clutch disk and throwout bearing. If you are doing this on the cheap, you may be able to keep the pressure plate. Pick up a clutch disk alignment tool. It looks like a short section of the input shaft of the tranny. This will help you align the clutch disk while you tighten the pressure plate. Then when you are trying to stab the tranny into place, things should be lined up.
There is a gasket between the tranny and the xfer. Best to go w/ OEM gaskets. There's nothing better.
If I'm not mistaken, you should have a split case xfer behind the trany. This xfer has to be taken apart to get it off the tranny. There is another set of gaskets.
A LOOOOONG extension for the tranny/bell housing bolts. A tranny jack would make it a lot easier. I'm told the H42 and xfer is very heavy.
While you are there, you might as well take the flywheel down and replace the rear main seal. The new seal is too cheap to not do this while you are there.

That's all that I can think of at this time. It's been a while since I have dropped a transmission. The last one that I did was about '95 w/ my mini. Things were a lot smaller then.
There have been several threads on swapping in an H55. The steps would be the same with out any adjustments for drive train length. HTH
The next time I touch my tranny, I hope that I'm swapping in an H55 when I do.
 
Hey thanks for the reply. Here is my list so far:

H42 before 10/85 - Check
Clutch Disk
Thowout Bearing
Pressure Plate (Maybe)
Clutch Disk Alignment tool
Transfer/Tranny Gasket
Transfer Gaskets
Long Extension - Check
Transmission Jack
Rear Main Seal


Thanks
-Wyo
 
4/85 is when the switch was made.


Dynosoar:zilla:
 
Hey thanks for the reply.

I have an '83 and my doner Transmission is from an '84 so I am good there.

Here is my list so far:

H42 before 10/85 - Check
Clutch Disk
Thowout Bearing
Pressure Plate (Maybe)
Clutch Disk Alignment tool
Transfer/Tranny Gasket
Transfer Gaskets
Long Extension - Check
Transmission Jack
Rear Main Seal
Front Seal for Tranny


Thanks
-Wyo
 
really your best bet for the clutch, would be picking a complete 'kit' up rather than piecing a kit togther.
a good kit would have the pilot bearing, throw out bearing, p plate, c disc and teh alighment tool. i might even be forgeting something.
a clutch job isn't something you should short change. it's not a hard job, but tough tto get too.

resurfacing teh flywheel is always good as well.

and since you're dropping the rear cross member anyway. tranny mounts could be changed too.
 
Don't know if you're into the 2lo mod, doing it while you have the tranny/transfer case out would seem logical.

2LO mod

Also check your seal between transfer case and tranny, if applicable for the 83 models...
 
I know you are on a budget but you could bet a T-Case rebuild kit from any of the vendors MAN-A-Fre or Sor. You will need to split the T-case in order to remove the old tranny so you might as well do that too.

Mark
 
I did not see a pilot bearing mentioned, but now is the time. The rubber clutch fork boot will be gooy and shot, replace it. Consider a new clutch slave cylinder-easy to do with it all apart. Look carefully at your speedo cable. It is much easier to replace with the tranny down. i totally agree that you should have the flywheel machined now too. Get a complete clutch.

It's heavy with the t-case. Don't think you can muscle it in.

Rebuild the t-case. The rebuild kit is about $200, but the t-case will be completely disassembled, so you may as well use new bearings, seals and gaskets when it goes together. If you are really broke, at least replace the t=case input seal, the speedo output seal, the rear output seal, and the o-rings on the idler shaft. Getting the high/low shifter back on the rail is a challenge. Be careful when putting it back together, or you will do it a second time.

Put a new shifter ring in the transmission shift tower. It's only a couple of bucks and prone to failure.

Take the tranny out with a transmission jack. I lift mine back in with an engine hoist through the passenger door. I also get a couple of bolts the same thread as the bolts that hold the tranny to the bell housing. Then cut the heads off, and use them as dowels to guide the tranny into place. Once in place, remove the dowels and replace with the toytoa bolts.

One last overlooked thing that makes a huge difference. The t-case linkage has a couple of bushings. One is square and plastic, the other is rubber. Replace these, and the weird shifter noise at speeed that all 60s seem to get will go away.

There is a small seal under the nose cover of the tranny input shaft. It takes 30 seconds to replace, so do that for sure.

Removing the cross member is a pain. I have found it easier to remove the frame support on the passenger side, as well as the cross member bolts.

Good luck.
 
x2 (good call Mark) on the t-case rebuild. The kit is about $200 and it has all the seals, gaskets and bearings. You have to totally disassemble the transfer case any way it would be a shame not to rebuild it.

Dynosoar:zilla:

Drew you posted like 30 seconds before I did!!!
 
I also get a couple of bolts the same thread as the bolts that hold the tranny to the bell housing. Then cut the heads off, and use them as dowels to guide the tranny into place. Once in place, remove the dowels and replace with the toytoa bolts.

Good luck.



that is a very handy trick. i've used it several times.
 
The nice thing about replacing the tranny as opposed to just pulling the trans/transfer assembly for a clutch replacement is that you can remove the transfer from the transmission first, then pull the tranny. Put the transmission back in first without the transfer, easier to manhandle just the tranny when stabbing the input shaft in the clutch. Then build the transfer onto the transmission.
 
Whew thanks for all the replies!

My List:

1. H42 before 10/85 – (Check, have it)

2. CLUTCH KIT= New Pilot Bearing, Throw Out Bearing, , Clutch Disc and alignment tool
Clutch Disk
3. Transfer to Tranny Gasket
4. TRANSFER CASE REBUILD KIT = t/case input seal, the Speedo output seal, the rear output seal, and the o-rings on the idler shaft, Plus ++

5. Rear Main Seal
6. Front Seal for Tranny

7. Rubber Clutch Fork Boot
8. New Clutch Slave Cylinder
9. New shifter ring in the transmission shift tower
10. T-case linkage bushings, the square plastic one and the rubber one.
11. Seal under the nose cover of the tranny input shaft.
12. Spare bolts to cut the heads off for alignment (Anyone now what size?)
13. Looonnnnnng Extension – (Check, have it)
14. Transmission Jack

15. Engine Hoist – (Check, have it)
16. Resurfacing Flywheel at machine shop.
17. 2Lo Mod (No Problem, have pneumatic cutoff wheel on hand)

Install the tranny first then the transfer? Is this the best way?

Side note: I had a fellow cruiser head drive my 60 and he thought all that was wrong was the Pilot Bearing was shot, I was under the impression that was part of the transmission and would be cheaper and easier to just swap in a newer used transmission, what do you think?

Have I doubled up on any of the parts, is something listed that will come in a kit?

Thanks!
 
#6 & #11 are the same thing.

#16 is best done by somebody that is familar with doing flywheels. there is a step on it that needs to be maintained.

if you have a spare tranny/transfer laying around you could prep them before taking the truck off line, there by shortening the down time, if not no big deal.
a shot pilot can make things sound worse then they really are.
you could pick a used combo up. prep that, then after the install sell, your used combo and probably come close to breaking even on that deal.
 
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No step like that on a 2F flywheel. The F flywheels have a step.

If the tranny is good, don't replace it.

I would re=install as a unit. It is much easier to rebuild the t=case with the transmission on the bench. Rebuilding the t-case is really assemblling the t-case on the back of the transmission.




you will need help to press the output shaft bearings off and on.
 
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I find it is easier to rebuild the xfer on the bench, rather than in the truck.

See post# 154

https://forum.ih8mud.com/60-series-wagons/139849-bj60-fj62-turbo=-bjt62-4.html





The third pic is a homemade pilot removal tool.


Fill the cavity behind the pilot with grease

Insert home made tool in bearing

Tap tool with hammer



The pilot will pop right out.

I did not make a mess doing it this way.

The puller I reneted from autozone wouldn't budge it.
 
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Could you point out what transfer linkage bushings I may need?
 

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