The Life & Times of Shasta (86 FJ60 conversion to HJ60)

[NCFJ]

That motor being at an angle can throw you for sure. Your mind just does not want to accept it. I saw something about that a while ago when reading a diesel build thread. I do not recall if there was a definitive reason given. Looks like you are having a good time and I am looking forward to seeing the end result. Johnny, I think you have oil in your veins

 

[GLTHFJ60]

That motor being at an angle can throw you for sure. Your mind just does not want to accept it. I saw something about that a while ago when reading a diesel build thread. I do not recall if there was a definitive reason given. Looks like you are having a good time and I am looking forward to seeing the end result. Johnny, I think you have oil in your veins

Yeah, the angle of the motor really threw me off. Definitive answer is here, it's tilted from the factory:

https://forum.ih8mud.com/threads/2h-into-late-fj60-drivetrain-alignment.815234/

 

[Tapage]

Oh crap, I didn't even think of that!! I'll do it this afternoon, then measure the diameter of the speedo driven gear and post up in that speedo gear thread.

big thanks dude .. but I guess the magic it's in the plastic gear count ..

 

[ontherxs]

Little late posting the second half of this past weekend's 2H install. After closing up Saturday we left scratching our heads. Could this possibly be the way the engine should be?

Big thanks to team Australia for confirming we we're good to go. Funky looking?Yes. Factory? Yes.

New day new koozie. So here it goes.

Tacked in both mounts. Passenger side.

Driver side.

Down goes the jack

And there she sits. No lifts no jacks and in the right place.

 

[ontherxs]

So what's next? Take it out again. Last time fingers crossed. Now to rebuild the transfer case

And it's out. It didn't want to come out. There was a lot of flex in the motor mount bushings because of the exit angle. It's going to be a full on wrastlin match to get it back in.

Time to clean all the remaining tx-case components.

We had to press out front output shaft. Then remove the companion flange.

 

[ontherxs]

More cleaning

Replace the front output shaft bearing, snap ring, and oil seals

Replace remaining oil seals

Pull the bearings off the rear output shaft.

This splitter proved to be more difficult than just pressing the shaft out.

 

[ontherxs]

Press out front and rear bearings

Using SST (flathead and mallet) remove rear output shaft pilot bearing.

Using SST #2 (plastic wrap) cover iPad with FSM reassembly instructions.

Install high gear and output shaft front bearing. Go to step 4

 

[ontherxs]

Step 4: Pressing the output shaft bearings.

This stack of old bearings is stand in for SST #3

Flip it over and repeat

This time adding clutch hub, sleeve, and rear bearing.

 

[ontherxs]

Almost done reassembly of the rear output shaft.

Replace pilot bearing and press in.

Press in front output shaft and install front gasket.

Turned out nice and clean. Ready for step 5

 

[ontherxs]

Time to reattach the front side case

Torque the inner bolts.

Install clutch sleeve with shift fork

Install rear output shaft front bearing retainer. Also install idler shaft with o-ring

Install idler gear, output transfer gear, and PTO gear

 

[jfz80]

Looks like time for step 6

Keep it up guys. Good work.

 

[ontherxs]

My phone died at that point so no more pics but from there we finished up for the day by installing the rear output gear, rear cover gasket, and rear cover.

Notice the bell housing and tranny are painted. Here are some pics of that process too.

It was definitely sun day fun day. Everyone including the dogs were toast.

Until next time when we finishing bolting, tourqing, and the PTO cover. This week hopefully we'll get to finish the welding on the engine mounts and shoot for final installation this weekend.

 

[Tapage]

did you have to add shims in order to have rear output shaft pre load .?

 

[ontherxs]

did you have to add shims in order to have rear output shaft pre load .?

We aren't quite to that step yet. That's next once I get all the remaining case bolt's in and torqued.

 

[GLTHFJ60]

We have the rear output bearing retainer shim that came out on disassembly. We'll assemble with that shim and test preload, then adjust if need be.

 

[mtweller]

We have the rear output bearing retainer shim that came out on disassembly. We'll assemble with that shim and test preload, then adjust if need be.

If it isn't right, LMK, I have a #3 and a #6 I believe in hand should they be needed.

R

 

[ontherxs]

Long day. Good news the 2h in.

 

[ontherxs]

 

[GLTHFJ60]

With some sushi to wrap the day up, it was a great day

 

[GLTHFJ60]

Oh yeah, it's in for good, as in not coming out again. This is a major accomplishment, considering the 2F blew up in February!!! What a saga this has been.