Just some pictures of the tranny and transfer. I had pulled it today to try to get my clutch done. 
The flat lever is for the original PTO.
The flat lever is for the original PTO.
Tranny / Transfer Pics
- Thread starter Cruiser_Nerd
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- #2
It was leaking pretty bad between the tranny and transfer, so I decided to separate it and reseal. Take off the top cover of the transfer and remove the four small bolts from the top. Nice rust, good thing those are straight cut gears, might be a little noisy otherwise. ;p
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- #3
Now remove the parking brake assembly and the two large bolts on the bottom.
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- #4
Now, DO NOT DO WHAT I DID! The output shaft of the transmission is retained by the transfer case! When you begin to pull off the transfer just give the output shaft a few taps with a rubber mallet to be sure it stays in the tranny. If you don't you'll hear the pleasant sound of needle bearings raining down inside your tranny. 
Here's a shot of the backside of the tranny......after I spent about three hours disassembling it, finding all the bearings and clutch keys that wandered, and reassembled it.
Here's a shot of the backside of the tranny......after I spent about three hours disassembling it, finding all the bearings and clutch keys that wandered, and reassembled it.
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- #5
Here's the front side of the transfer case, for all of you that haven't seen it in it's naked glory. 
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- #6
Nobody's enjoying my misery? Put the shifter tower on last night............yep, had the 3 - 4 dog in backwards.........nope, removing the input shaft doesn't buy enough room........had to remove transfer case and disassemble. 
Where's the maniacal laughter smiley????? 
Put the shifter tower on last night............yep, had the 3 - 4 dog in backwards.........nope, removing the input shaft doesn't buy enough room........had to remove transfer case and disassemble. Where's the maniacal laughter smiley????? 
Living in the Past
SILVER Star
Hey Jim since your such a expert now why not pull it apart again and measure it for a adapter for a two speed transfer case 
. I'll want until you get it back together again to ask you for the true tail shaft length. 
. I might want to put a Fairey overdrive in there too 
.
John
. I'll want until you get it back together again to ask you for the true tail shaft length. . I might want to put a Fairey overdrive in there too . John
The splines look good .
.
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- #9
You did notice the three different diameters on the output shaft right? John, I'll send you the old gasket, make an adapter from that! 
Living in the Past
SILVER Star
Jim does the idler gear that is exposed drive anything? Kind of funny seeing the gear sticking out.
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- #11
Not sure what you mean John. In the transfer the input gear slides on the output shaft of the tranny for in/out 4wd. The idler is always engaged with the gear on the front output shaft.
The thingy on the back of the transfer is the speedo drive gear.
The thingy on the back of the transfer is the speedo drive gear.
Living in the Past
SILVER Star
In your third picture with ebrake / speedo housing removed you can see a couple of teeth of the idler gear next to the upper bolt you remove to remove the transfer from the transmission. Is that not the idler gear. Just seemed funny that the hole for that bolt is so large that it exposed part of the gear.
John
John
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- #13
Ah, I see what you mean. Yep, that's the idler. Can't think of a reason for the hole being that large other than to get two fingers in.
Jim,
Do you have a FJ25 service manual to refer too when doing this work? I've rebuilt quite a few three speed FJ40 transmissions and transfer cases, and can almost disassemble and put them back together in my sleep. Of course, I've got all the reference material to make the job easy. The FJ25 transmission and transfer case is quite a different assembly, and I bet the service manual would be a valuable item to have.
Do you have a FJ25 service manual to refer too when doing this work? I've rebuilt quite a few three speed FJ40 transmissions and transfer cases, and can almost disassemble and put them back together in my sleep. Of course, I've got all the reference material to make the job easy. The FJ25 transmission and transfer case is quite a different assembly, and I bet the service manual would be a valuable item to have.
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- #15
landcruiserdude said:
That, is probably the understatement of the year. Do you have a lead on one? Cruiser_Nerd said:
No, I sure don't. The earliest service manual I have is a 1963 manual (Black and Gold cover), which is very extensive and well documented. It shows the early three speed transfer case (four bolt cone cover), but it's closer to the regular three speed cases than the FJ25 center output system. Given these early FJ40s have a lot of similarities with FJ25s, I'm sure there is some cross reference material hidden in there somewhere.
Probably not since the 25 tranny is a 4 speed and the 25 t-case has no low range.
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- #18
Lance, really the only later manual that's a help is the early F engine manual, keeping in mind some specs could be different. Most everything else is different between the 40 and 25. A reprint of the FJ25 electrical manual is available from SOR.
Eric, you gave me a lead on a manual, still need to follow up on that.
Eric, you gave me a lead on a manual, still need to follow up on that.
