Tranny to split TC shaft stuff pic needed

[woytovich]

Tranny to split TC shaft stuff pic needed.

I am having a brain freeze. I need a picture or a clear diagram of what goes on the tranny output/TC input shaft (the one that goes from the tranny into the split transfer case) and in what order .

Does something go between the bearing (that seats into the TC housing) and the oil seal?

How deep does the oil seal go into the TC case? Does it bottom out? Does it need to go all the way in/flush?

What does the first big gear that you put on the shaft from the TC side ride on? (it's called the "TC input gear" I think?)

Arrrggghhh.... this is what I get for letting this sit for 6 months before trying to put it back together....

Thanks,
Mark

 

[FJ60Cam]

...these help at all?

 

[2mbb]

Hopefully these will help.

The seal gets fully seated into the front half of the transfer case.

The exploded diagram shows the input gear sequence at the top. The front of the vehicle is to the left. The first item is the seal, next is an o-ring (just for the automatic transmission), then the input gear, then the spacer then the PTO gear, then the bearing. The washer and nut go on after the rear case and rear output flange is installed. An SST is used to hold the rear output flange and therefore the input gear from turning so the nut can be properly torqued. My homemade version of the SST shown below the transfer case in the bottom picture. It's just a lever arm that can be bolted to the output flange bolt holes.

 

[GLTHFJ60]

Wierd. In neither case is there a PTO gear. Like both before me have said, the oil seal gets pressed in, then the TC input gear with the wider side towards the transmission, then the spacer, and in my case the PTO gear, with the longer side facing the transmission, and finally the bearing.

 

[woytovich]

Thanks...

So the input gear rests on WHAT on the tranny side? Does it ride against the case just outward of where the seal goes?

Does the part of the input gear that protrudes into the seal rest on anything? (Does it bottom out?)

Hopefully these will help.

The seal gets fully seated into the front half of the transfer case.

The exploded diagram shows the input gear sequence at the top. The front of the vehicle is to the left. The first item is the seal, next is an o-ring (just for the automatic transmission), then the input gear....

 

[woytovich]

...these help at all?

I can see a spacer inside the seal (in the pic with the input gear removed)... what part is that?


EDIT: On second look that is the bearing I think...

 

[2mbb]

Wierd. In neither case is there a PTO gear. .

Yeah. The FSM shows the PTO gear, but I don't think it came as standard equipment in the US spec trucks. The spacer must be longer when the PTO gear is missing.

 

[woytovich]

Yeah. The FSM shows the PTO gear, but I don't think it came as standard equipment in the US spec trucks. The spacer must be longer when the PTO gear is missing.

Yes, there is a smaller spacer that is used with the PTO gear. I have the small spacer and the PTO gear in mine...

 

[woytovich]

So I think the input gear rests on the bearing. The input gear, bearing and input shaft all turn together. So my question really is: Does the input gear touch the TC housing or is it held away from it a little bit. In my TC the aluminum that would be the contact point shows wear... as does the input gear.

 

[Cruiserdrew]

The PTO gear comes on the later split cases, but at least on the 84 I took apart recently, there was a long spacer instead of the PTO gear.

 

[GLTHFJ60]

It is held away a tiny bit from the TC housing. There is a longer and a shorter side of the input gear, and the longer side slides into the transmission and bottoms out on something ( bearing? ) that prevents it from riding on the TC housing.

I have the PTO gear on my 87, and Mark's is an 85. What determined whether or not each truck was equipped with a PTO gear?

 

[woytovich]

This is an early TC that I am rebuilding. The TC in my 85FJ60 did not have the PTO gear (I think I added one "just in case" when it was rebuilt in preparation for install there with the 5 speed) This TC came from an early (83?) FJ60 and is going behind an H55f into my FJ40.

I'm concerned with the wear on the input gear and TC housing. Not bcause it will cause any problem going forward but I want to know what would have caused it to happen before. On that note the oil slinger that sits on the idler shaft gearset had gotten destroyed on this case (it was in the case in pieces along with a bunch of metal shards when I took it apart) Maybe some of the slinger got in there and cause the wear?

 

[2mbb]

On transfer cases up to 10/82 there is a collar and ball that goes onto the transmission output shaft first. However, this is not used in later transfer cases. My 1985 case does not have this. However, I have the H55F transmission and I didn't take the transfer case apart until after the H55F was installed (by someone else). One of the manuals I have shows a collar on the transmission output shaft for the H42 transmission. And the parts microfiche shows a spacer to the rear of the transmission output bearing on the H42 but not on the H55F. The collar and ball have different part numbers than the output shaft spacers so I don't know if they are the same or different parts