We’ve had a number of inquiries for these recently so I thought I’d start a thread.
As most of you know, the most common transfer case leak on any FJ 40, 45 or 55 is typically the rear extension housing and E break area.
Quite a number of years ago somebody came up with the idea to put two seals in the extension housing instead of one. This requires machining the rear seal bore to create room for a second seal.
We offer these housings ready for install; in kit form. The kit includes a machined housing that has gone they the wash, been bead blasted and painted with 2 seals already installed. We also include a set of 4 Allen bolts to attach the e-brake backing plates; the factory hex bolts are a royal PITA and prone to rounding off. We also include a new speedo o-ring, extension housing gasket and stake but as well as 2 drain plug crush washers. That way every part needed for the job is included.
The kit costs $149.98 plus $12.50 shipping CONUS. There’s a $200 core charge that will be refunded if a serviceable used extension housing is returned to us.
Install is pretty straight forward.
1) Drain T-case. Remove e-brake drum, backing plate, speedo cable, speedo bullet and rear extension housing along with shim(s).
2) Clean gasket surface on t-case. re-install shim and new dual-seal housing. We like to use Loctite "formula 518" gasket sealer on both sides of any transmission or t-case gaskets ( red sealer shown in pics ).
3) Install both new o-rings supplied in the kit. One on the outside of the speedo bullet, the other on the inside. Then slide the speedo bullet back into the rear extension housing. We like to add a small amount of automotive silicone on the outer o-ring to help the speedo bullet slide in place.
4) Our kit also contains 4 allen bolts; one being shorter than the others. These are used to re-attach the e-brake backing plate ( since the factors 12mm hex-bolts are a royal PITA! The shorter allen bolt needs to be installed on the top left or it'll bottom out in the housing. A small drop of loctite on these bolts is a good idea.
5) Replace the ebrake shoes and any hardware if necessary. Clean the e-brake drum really well, then add a small amount of automotive silicone in the splines in the drum before installation. This will seal the splines and keep oil from leaking out of the rear of the drum. Torque the stake nut to 60-65 foot pounds.
6) It's a good idea to wait at least 12 hours before filling the t-case with 80/90WT gear oil to give the silicone a chance to cure. The kit includes 2 new crush washers for the drain and fill plugs.
Some pics below.
We can also supply new ebrake shoes as shown below.
Let me know if you have any questions, we’re happy to help.
Georg
Valley Hybrids & Cruiser Brothers
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