Transfer Case Carnage

[vk7ybi]

Hi All,
Over the weekend I busted my transfer case.. Its snapped in half and has other bits missing.. I have a replacement case to go in, but I'm thinking it might be a good idea to install a saver.. Being in Aus, I've never seen a source for one of these.. Does anyone know where I might get one over here?

Might be a good excuse to install that Orion I always wanted.. Same problem though, availability, freight and exchange rate at the moment make it not so attractive..

 

[35inchoverdrive]

PM Poser on the board. He makes them, and I wouldn't think shipping would be too terrible since they aren't huge.

 

[Cruiserdrew]

Poser made mine but I think is out of them.


Georg--Orangefj45 is now making a similar design. Send him a PM, he's a reliable source too.

 

[BrianSanDiego]

Georg--Orangefj45 is now making a similar design. Send him a PM, he's a reliable source too.

X2 on Georg. Good part, fair price, quick shipping and pleasant to deal with.
B.

 

[Seth_O]

X3 on Georg - I haven't bought this particular part from him, but have bought lots of other components (including a transfer case ) and it's been a great experience every time. Highly recommended....

 

[1979 BJ40]

transfer case stuffed

hey
dose anyone know how hard is it to put a new transfer case in 1979 bj40 the one in there is rooted. and dose anyone know if there is a 5 speed box that would bolt stright on

 

[vk7ybi]

I guess, looking at them, they cant be that hard to make.. Some 6mm plate, a drill press, grinder, welder and some time a bloke could make one.. Now that I have the case out, upon inspection I can see how its failed and the function the saver attempts to perform..

I separated the case from the gearbox in there, it was a bit awkward to remove the half case over the output shaft.. I'm a bit worried that with a new seal and extra weight of the complete case I might have trouble without damaging the seal.. Is there much to be gained from dropping the rear engine mounts and lowering the transmission a bit?

 

[vtcruiser60]

I guess, looking at them, they cant be that hard to make.. Some 6mm plate, a drill press, grinder, welder and some time a bloke could make one.. Now that I have the case out, upon inspection I can see how its failed and the function the saver attempts to perform..

You could do this....but my advice is to go with Georg's set up. I would purchase both the t-case saver and the nose cone saver from him. I suspect shipping will be something like $12 to Australia...it is very cheap through the US postal service.

Here is a write up to the new nose cone savers....https://forum.ih8mud.com/merchandise-storefront/245075-nose-cone-savers-one-piece-cruiser-case.html

Good luck...

 

[flaminbandit]

your in aus so dont bother with the single piece weak as case find yourself a later model 4 speed and split case or even better a 5 speed and split case from a bj42

 

[allan man]

Hi all, How are you folks breaking your transfer case? is it that weak?or are they being pushed to the limit?I was just a little concerned because i recently installed 33 inch tires and plan on doing a front and rear locker next week, its a 1974 FJ 4 speed,i did the 2low mod already on the transfer case,should i be considering this PLATE for the transfer case? Thanks in advance.

 

[Bodean]

YES! Get the case saver from orangefj45. If you are going to wheel it then it is cheap insurance. Easy to install and comes with all bolts needed for installation.

Later,

 

[Trollhole]

Hi all, How are you folks breaking your transfer case? is it that weak?or are they being pushed to the limit?I was just a little concerned because i recently installed 33 inch tires and plan on doing a front and rear locker next week, its a 1974 FJ 4 speed,i did the 2low mod already on the transfer case,should i be considering this PLATE for the transfer case? Thanks in advance.

I'm betting he was driving a cruiser with a v-8.

 

[allan man]

Does the transfer case have to be dropped? to put the transfer case saver ,or can i access it from the top by removing the transmission cover?

 

[pb4ugo]

Hi all, How are you folks breaking your transfer case? is it that weak?or are they being pushed to the limit?I was just a little concerned because i recently installed 33 inch tires and plan on doing a front and rear locker next week, its a 1974 FJ 4 speed,i did the 2low mod already on the transfer case,should i be considering this PLATE for the transfer case? Thanks in advance.

The saver might be something to consider. Call it insurance. I've seen stk motors and big tires break them too. If your putting a locker up front and using stk birfields, they will break 1st.

I've broken a number of them w/a V8. Some broke easier than others. I have 1 I've beat to death,that has been modified for strength(no saver), that hasn't.

 

[dgangle]

..easy to copy and considering your location, maybe your most economical and quickest alternative. Everyone I have ever broke was from abuse from bouncing the truck under load. Fix this and the weak link will reappear somewhere else...birf, inner axle, pinion, DS, .........................

 

[vk7ybi]

This was in my 2F hard top, specs in the sig line.. Tyres were 31 wranglers @ 10psi.. No front locker engaged.. Brother driving in a sandy bog, 3500-4000rpm clutch drops in forward and reverse.. SNAP! Just too rough, I certainly dont treat my vehicle like that, but I guess because he was driving and it wasnt his, he thought he could..

Yes, I would prefer to shift the weak link elsewhere, had to be towed home thorugh 20k of sand, 15k of trail and 250k of road.. If I had drive to atleast one axle I couldve got myself home..

Either way I go, I wont have time to install a saver, I need this going before this weekend.. I'll install one eventually, as insurance..

 

[bsmith123]

xfer case saver

heres mine

you can get them on ebay and several mud vendors have them too but if a fellow mudder makes them I would do that

didnt know anyone was making them when I got mine

you can install them with the cover off. The one I got came with longer bolts to compensate for the thickness of the saver

 

[DSRTRDR]

Hi all, How are you folks breaking your transfer case? is it that weak?or are they being pushed to the limit?I was just a little concerned because i recently installed 33 inch tires and plan on doing a front and rear locker next week, its a 1974 FJ 4 speed,i did the 2low mod already on the transfer case,should i be considering this PLATE for the transfer case? Thanks in advance.

I wheel 33s, lockers front and rear, 4.5-rated trails in Moab, been there 6 times, and otherwise I wheel all kinds of trails in AZ - it's not like you HAVE to break stuff

 

[Alz Toy]

Go back a couple of pages, to the " Do I need a crossmember " post. Go to the bottom of page, and look at the one LC Hammer posted a pic of. Interesting setup. Al

 

[vk7ybi]

So, I decided to make myself a saver, all out of scrap, cost nothing but time.

I cleaned up the replacement case, washed it inside and out..

Installed new input seal and rear output seal.. Dont have the machinery to do the double seal trick..

Installed extended breather..

Installed new hand brake shoes and freshed up the drum..


Learned that the case doesnt go in too easily with the saver installed, so had to remove it before installation.. I didnt move the transmission, it was a tight fit though..

I also learned that the PTO cover bolts are longer by the thickness of the saver plate, so I swapped the 5 saver plate bolts for the PTO cover ones to regain the threads lost to the plate, helpful hint for anyone else making their own saver..