Split case / trans seal replacement question

[Ambrew]

Hi All,

H55 over full, tcase low. I researched and saw the bypass hose but really I dont love the idea since it could blind side you on the trans side.

Questions:
Is is relatively easy to replace the seal while leaving the trans in the truck (bj42)? or is it better to drop the trans?
This has less than 10,000km since I rebuilt it. Any ''consumable'' parts i should be aware of? All the bearings are new.
I lost my H55 and tcase books in a flood. They seem harder to find... ( I am hoping for a copy of the book, I realise I can find a pdf online... )

Opinions from those who have done it please!

Andy

 

[Living in the Past]

Being a drum from a hand brake on the T case doesn't clear the torque tube behind the case think it was be hard to remove the back of the transfer case to remove the transfer case from the transmission while in the truck.

 

[Ambrew]

The Pbrake is on the axle on this truck, so no drum on the Tcase. I added an h55 to an 81 bj42, so it has the split case.


Mulling it over, and the doubts are setting in: Why would this seal go bad after such little use? hmmm.... Poorly installed? not enough use? bad luck?

 

[Godwin]

Pull the rear half of the t-case to replace the seal. Use a seal from a FJ62 which has a double lip and will help to prevent the oil migration issue..

 

[Ambrew]

Just saw your thread. 90316-48003 it is then. Thanks!

Next question: is there a gasket set or only a rebuild kit? I see 4 different front gaskets alone... gonna keep looking.

 

[4Cruisers]

Just saw your thread. 90316-48003 it is then. Thanks!

Next question: is there a gasket set or only a rebuild kit? I see 4 different front gaskets alone... gonna keep looking.

You can buy a gasket and seal kit from Toyota, you have to do some legwork to get the correct part number.

Part Number 04331-60040 through 10/82, 04331-60060 10/82 through 11/84, and 04331-60080 11/84 through 10/85. 10/82 was when the transfer case was changed to add the provision for the 5-speed oiler cup. I don't know what the 11/84 change entailed (Canada specific), but the idler shaft changed from 34mm to 38mm in 04/86.

Check this out:

Cruiser Outfitters

 

[4Cruisers]

Update to above, including HJ60 models.

04331-60081 10/85 through 08/86 and 04331-60160 08/86 through 08/87.

 

[Living in the Past]

The Pbrake is on the axle on this truck, so no drum on the Tcase. I added an h55 to an 81 bj42, so it has the split case.


Mulling it over, and the doubts are setting in: Why would this seal go bad after such little use? hmmm.... Poorly installed? not enough use? bad luck?

I realize where the parking brake is located on 8/80 short and mid wheel base 4X series. I'm trying to point out clearance is a issue between the transfer case and adding a five to one with a hand brake is a problem. I do not have a five speed installed in a 8/80+ 4X series but think pulling the back of the transfer case off so it can be removed from the transmission might be a real challenge. Then lining everything up to install even a greater challenge. Since no else has answered the question wether to pull the transmission I would crawl under you BJ42 and do some measurements on clearenaces for removing the back half of the transfer case. Not sure about the B engines but on a F engine would use this as a opportunity to replace the rear seal on the engine. These seem to be like a Harley Davidson motorcycle. If it not dripping oil you better check the oil it's probably low.

 

[Ambrew]

Indeed. Spoke to Kurt @cruiseroutfitters and he brought up the same concern: no room for assembly. His suggestion was to tilt the engine and take the trans out.
The whole truck was rebuilt 10,000km ago. I agree though, if the trans comes out the rear main gets changed. it is leaking.

4Cruisers: as above. Kurt has all the parts in stock, so i will take it apart and see what i need.

Apparently, if the input gear of the tcase has a worn seal surface, it may be allowing or at least helping the oil pump out of the tcase. More to follow as I take it appart!

Thanks!

 

[nogo]

Pull the rear half of the t-case to replace the seal. Use a seal from a FJ62 which has a double lip and will help to prevent the oil migration issue..

Good info with pics!..... Transfer case input seal comparison

 

[nogo]

You can buy a gasket and seal kit from Toyota, you have to do some legwork to get the correct part number.

Part Number 04331-60040 through 10/82, 04331-60060 10/82 through 11/84, and 04331-60080 11/84 through 10/85. 10/82 was when the transfer case was changed to add the provision for the 5-speed oiler cup. I don't know what the 11/84 change entailed (Canada specific), but the idler shaft changed from 34mm to 38mm in 04/86.

Given there's a few different gasket / seal kits, I'm thinking you'd need to use the production date of the gearbox / transfer case as a guide to what kit to purchase as opposed to the vehicle VIN plate.