Sheila's evisceration and birth of an HJ62 -> Tofudebeest

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Transfer case access hole, new "breather":
P1010019-3.jpg

Closer view. Note, the top right bolt is missing:
P1010016-3.jpg

Cover:
P1010020-5.jpg


Ok, about that missing bolt... The top right bolt was missing, and the one to its left (as seen in picture 2 above) was backed out about 1/2". Much more and it would have been lost too. I tightened the loose one, of course. Then, I got a bolt (from Mel Lowe) which threaded perfectly into a H42 case on the bench (the threading begins immediately, not deep into the hole), and the bolt went through a spare transfer case and emerged about 1-2 inches on the other side, so it appeared to be the right bolt. I even placed it above the hole in the case in my truck, to be sure the cases were the same and that the bolt would go all the way through and reach the threaded hole in the transmission case. All looked good. But, insert the bolt, it goes all the way in, never bottoms out and gets no resistance, as it would if the threaded hole were somehow stripped out. It just turns. Nothing. Further, pull the bolt out and it has gear oil on it, and I'm not sure it should. Lastly, as you can see, gear oil does leak out of this open hole. WHAT'S GOING ON HERE?! Anyone?
P1010018-4.jpg
 
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Tofudebeest said:
Ok, about that missing bolt... The top right bolt was missing, and the one to its left (as seen in picture 2 above) was backed out about 1/2". Much more and it would have been lost too. I tightened the loose one, of course. Then, I got a bolt (from Mel Lowe) which threaded perfectly into a H42 case on the bench (the threading begins immediately, not deep into the hole), and the bolt went through a spare transfer case and emerged about 1-2 inches on the other side, so it appeared to be the right bolt. I even placed it above the hole in the case in my truck, to be sure the cases were the same and that the bolt would go all the way through and reach the threaded hole in the transmission case. All looked good. But, insert the bolt, it goes all the way in, never bottoms out and gets no resistance, as it would if the threaded hole were somehow stripped out. It just turns. Nothing. Further, pull the bolt out and it has gear oil on it, and I'm not sure it should. Lastly, as you can see, gear oil does leak out of this open hole.
Click to expand...

I would assume that the threads are indeed stripped. and it is leaking by the gasket there. I think this is one of those gaskets that also go around the hole where the bolt goes in. No bolt-not enough pressure to seal-leak.
The only ways to fix this would be either a different housing, or drilling and tapping it a little bit bigger. I don't think you can do this while it is on the truck though.
No idea if helicoils would be strong enough. These bolts are not torqued hard.

You might get away by using gasket sealer on a new gasket.
cheers,
J
 
Didn't want to hear this. I'd VERY MUCH like to avoid dropping this transmission, but if I have to, well...I'll get to use the transfercase rebuild kit I have sitting on my shelf...

I just can't imagine stripping those cast iron threads out of that transmission (especially since I bought it in 2007, and it was a new crate transmission)...and do so so severely that the bolt would just pass right on by as if it had no threads at all. I mean that the bolt slides by with no more friction than going through the transfercase hole. Like a popsicle thrown down a hallway...
 
Try fully removing the remaining bolt and comparing it to the one you are attempting to use?

Did this happen since you put this drivetrain in or has it been missing for an unknown amount of time?
 
This drivetrain went in in 2007, and was used for about 8 months until it sat for the Tofu conversion, and back on the road for ~1 yr. Truth be told, I have no idea how long that bolt was missing.
 
Tofu, I have my freshly pulled engine/trans/transfer on the floor.
If you need me to pull that bolt and give you an exact size let me know. I'll do it tonite if you need the size.
 
This thread reminds me of the woman here who got in trouble for her intended vanity plate.

iluvtofu.b1iqu3z2sq0okc0swc8g4cggg.27ty3bfoxo9wgcowoccowg0kg.th.jpeg
 
That bolt from tip to tip is about 7 3/16" long. It has 2 washers, a small and larger flat washer under cap.

It has about 1 5/16" of thread at the end.

Looks like it's an M12 X 1.25 thread pitch.

It also has some of that gritty OEM thread sealant on the threads.

Hope that helps.
 
Sidenote- this of course being in my 87 that has the OEM H42 and steel spacer between the trans and transfer case........
 
Joe_E said:
That bolt from tip to tip is about 7 3/16" long. It has 2 washers, a small and larger flat washer under cap.

It has about 1 5/16" of thread at the end.

Looks like it's an M12 X 1.25 thread pitch.

It also has some of that gritty OEM thread sealant on the threads.

Hope that helps.
Click to expand...

It does. And well, F me (not you, just in general). The size and pitch are right, but the bolt I tried was no more than 4" long.

You sure you are looking at the correct bolt?
 
You have it correct. But, I'm seriously hoping the bolt I tried was just too short somehow. Seriously, even with an impact, there's just no way those threads were stripped and stripped so badly that there's no resistance passing a bolt through. No effing way.
 
Googled this up Tofu-

H55F transmission into an 85 Toyota Land Cruiser | OlympiaFJ60

Google Image Result for http://www.olympiafj60.net/wordpress/wp-content/uploads/2009/01/center_bolt_hole.jpg

"Also you will need to modify the transfercase shifter or get the shifter from the later H42. I did not feel comfortable cutting and welding the cast lever and so I turned to SOR for the lever parts. You will also need the longer transfercase to transmission bolts from the later transfercase. While it is possible to use the 4speed shifter lever, the 5speed lever is a better fit and does not require modification to miss the dash."
 
Joe_E said:
Googled this up Tofu-

H55F transmission into an 85 Toyota Land Cruiser | OlympiaFJ60

Google Image Result for http://www.olympiafj60.net/wordpress/wp-content/uploads/2009/01/center_bolt_hole.jpg

"Also you will need to modify the transfercase shifter or get the shifter from the later H42. I did not feel comfortable cutting and welding the cast lever and so I turned to SOR for the lever parts. You will also need the longer transfercase to transmission bolts from the later transfercase. While it is possible to use the 4speed shifter lever, the 5speed lever is a better fit and does not require modification to miss the dash."
Click to expand...

I am gonna study the picture, thanks. The text is old, old news. The "longer bolts" were purchased from Cruiserparts.net James along with this case and transmission and assorted parts. But, it took him three tries to actually ship them correctly. I know the bolt was correct when originally installed, it just backed out from the diesel vibration.
 
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The spacer was put on the H42 to make it the same length as the H55 so toyota didn't have to produce 2 variations of the driveshafts, crossmember location, etc. The 7" bolt is the correct bolt. Tofu, the bolt you tried is most likely too short.
 
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