Split-Case Mash up of gears and different years halves?

[TLC Norway]

So, im finally getting around to checking out the split cases i've got.

#1 is 38 idler behind a H55f in the 88' HJ61 with vac shift.
#2 is 38 idler behind a 150R from an 87' Lj73 with vac shift.
#3 is 34 idler behind a H42 on a 2H from an 82' HJ60 with manual shift.

#1 has started to make grinding noises, especially when engine braking and shifting in and out of 4wd.
There's also a smaller grind when i hit larger bumps, sounds like if the driveshafts are pushing on the output bearings. Had the shafts off and felt for slack in the u-joints and outputs, but coud not feel anything. Shafts also slide well on the slpines.
Ordered a complete rebulid from George @orangefj45. All parts are in.

This one has bearings instead of the bushings on the idler shaft, i guess #2 has them, #3 should not have them.

So now i drained the nice oil and pulled the PTO cover off the #2 case and counted theeth, just for the sake of getting photos in here i took theese:

White marker shows me counting several times...

this is the end result:
Split case marked 7B 994 witch is 1987 Feb #994 if memory serves me right in decoding the stamps.
And if my counting and calculations are right, this has a total low reduction of 2.2764.
After recalculating, it should end up at 2.2956, right?
Can someone confirm my calculations?

I dont know what the Ratio is in the #1 case in the 61, but that makes for a nice shift if they are the lower 1.96.

So, i wanna pick off the 61 case, or rebuild it under the rig.
(WHEN, is depending on if the noise continues to get worse, or if i somehow can find a garage to stay in for a few days. Wont do it on the ice)
The 61 is now a DD, so i cant have much downtime. next weekend i have friday night and saturday free.

Ill use the best gears out of the two 38mm cases, and the reason why im mentioning the #3 older/early split case is that i wanna go manual shift.

I've read most threads concerning this, but i still have a few questions.
1:Can i bolt the linkage of the shorter h42 case onto the h55f case?
2:Seems like i can use the 2-4wd shifter arm from the early split case?
@beno probably has the bushings and whatnot for that?
3:Will the tranny hump plate in the 61 fit the movement of the transfer stick?
4:Is there anything else i need to do to be able to mount dual stick shift later on?
5:Is there a 38mm case i can hunt down that already has the the maual shift detent ball, nowhere i can get the tap in short notice.


Tag a mate who knows s***:
@orangefj45 , @cruiseroutfit , @reevesci , @GLTHFJ60 , @Tapage and so on.

 

[LAMBCRUSHER]

late fj60 case should have 38Mm idler and have manual shift detent ball

 

[TLC Norway]

late fj60 case should have 38Mm idler and have manual shift detent ball

Yess, but this is not fj, it's HJ.
As in it does not have the detent ball due to vac shift.

 

[LAMBCRUSHER]

late fj60 case should have 38Mm idler and have manual shift detent ball

 

[LAMBCRUSHER]

thought you were asking if there was a case you could find to use the front half of from along with the back half of your hj61 case with 38mm idler bore and vacuum shift front half.

 

[TLC Norway]

thought you were asking if there was a case you could find to use the front half of from along with the back half of your hj61 case with 38mm idler bore and vacuum shift front half.

Aah, I see... would it be enough with the front half?
And will that idler shaft have bearings or bushings?

 

[LAMBCRUSHER]

my understanding is, that if you want to take a vacuum shift bearing supported case and convert it to manual shift, it takes a front half of similar idler shaft bore. all the bits that go in the back half stay there, the idler shaft will use the bearings that it has now, and the front half with the manual shift stuff just bolts on in place of the vacuum shift front half. personally, I don't have a problem with the vacuum shifting case, so I kept my late 38mm bore case intact as a vacuum shift case.

 

[TLC Norway]

yeah, thanks. I needed to hear that, i was just under the impression that only the vac shifted cases had idler bearings.
Well, i'll see if i can find one, but i guess not. Not around theese parts.
So the 2nd option would be to find the correct tap, add detent ball and source those parts from the early split case.
That would involve me opening all three transfers if i wanna do it this weekend.
3rd option would be to just rebuild (maybe steal the 2.29 gears from the other case) and run the vac shift.

In the LJ73 the vac shift was smooth and only took half a second to engage, even at low rpms with binding in play.
Now, the 61 has had a longer shift time, up to 10 seconds or longer.
That could be caused by a worn mesh on the synchro gears, right?
I've tried shifting with a mechanical vac gauge hooked up, and it does seem to have proper vacuum with no leaks.