Transfer case issue 80series 1991

This site may earn a commission from merchant affiliate
links, including eBay, Amazon, Skimlinks, and others.

C

Crusing

Joined
Jan 1, 2016
Threads
1
Messages
6
Location
New zealand
Hi all.
Am having trouble diagnosing an issue with my 1991 landcruiser 80series. I was driving along, towing under heavy load when I lost all drive. There was no serious clanking or banging when it happened just no drive. Been in the middle of nowhere, I locked the transfer case and drove home( transfer hf2a full time model). I've so far stripped down front and rear drive lines trying to find the issue, but everything (drive shafts, diffs, splines, axles, flanges seem to be fine). So far I have no drive when the transfer is unlocked and IT MAkes a horrible clank when selecting a gear (auto transmission). It drives fine with no clunk when the transfer is locked yet does not bind up on sealed road. Has anyone had a similar issue? Can I be sure its in the transfer?
 
More information required.
When you say you locked the transfer case do you mean pressed the center diff lock switch?
If it does not bind up with the cdl engaged then something is broken in the drive train.

Jack each wheel up off the ground and in park with the cdl engaged.

Try to turn the wheels. The one that turns is the one not connected to the rest of the drive train.

The fact that it drives with the center diff locked points to something broken but does not isolate it to front or rear.


Sarmajor
 
That sure sounds like the drive plate on one of the front knuckles has stripped the splines. Pretty common. Pop off the grease caps on both front wheels. Then have someone try to drive it with the transfer case unlocked. If the outer end of the Birf is rotating without the wheel turning , then you have found the problem. Cheap and easy to replace.
 
I mean centre centre diff lock button on dash.
With the cdl engaged I have been around the vehicle and jacked up each wheel. The fronts won't turn more than a inch eather direction. Both the back wheels won't turn forward but will spin freely backwards.

I have aready had a mate help me check the front drive flanges and splines. Whilst they are quite worn they are far from stripped.

So far I have been learning towards something been stripped in the transfer??
 
The back wheels should do exactly what the front wheels do in this setup.
Check the rear wheels again while observing the rear drive shaft. If it turns then the problem is in the transfer case. If it doesn't turn then the problem is in the rear differential.


Sarmajor
 
Just jacked the rear end again with diff lock locked. Both wheels spin freely backwards and forwards! The rear drive shaft rotates with the wheels.
Seen this is showing the issue been the transfer what could have possibly gone wrong? I was lead to believe that they are a robust unit?

Also am I best to simply swap out the transfer for a new second hand one or have this one rebuilt?
 
Remove the speedo sensor at the rear of the transfer case and have a look in the hole while you rotate the rear drive shaft by hand.
You could also drain the oil and see what comes out the hole.
Lasso does the problem continue to exist if you put the transfer into 4LO.

Not much to the transfer case really and it is fairly easy to get out of the truck. It is heavy though. I have removed mine before in my workshop using a trolley jack and basic hand tools.
You can't make it more broken.


Sarmajor
 
The full time transfer case has an inbuilt centre differential, witch in my case is shagged.
As this is my daily vehicle I will be purchasing a new transfer and simply swapping them over.
I am going to stripp this unit down tho to find the cause of the problem.
Thanks for all the help and advice. I hope to have this solved soon!
 
OMG. Really people?
With all 4 tires on the ground and the transfer case UNLOCKED. Put the car in DRIVE and have someone look under the car. If the front driveshaft is spinning when you apply throttle, then the problem is in the front end. Most likely stripped drive plates like previously mentioned. Turning the wheel by hand is not applying any real force to the problem joint.
It would be EXTREMELY unlikely for the transfer case to be the issue.
 
Hey Jonheld,
with transfer case unlocked and all wheels on the ground, I put her in drive and NO drive sharf spin. Front or rear.
Cheers
 
Crusing said:
Hey Jonheld,
with transfer case unlocked and all wheels on the ground, I put her in drive and NO drive sharf spin. Front or rear.
Cheers
Click to expand...
Did you apply throttle and try to drive forward?
With the transmission in PARK are you able to shift between low and high range?

Chock the wheels.
Remove the 2 drive shafts from the transfer case output flanges. Engine off. Transmission in neutral.
With the transfer case unlocked, the 2 output flanges should react exactly the way an axle differential would react if both wheels were off the ground. If you manually rotate 1 flange, the other flange will rotate in the opposite direction.
If you lock the CDL they should be locked together.
 
Last edited:
Hi all. Just an update
After having a couple of days off, a mate and I, took the drive shafts off and pulled the back off the transfer case. What we found was i have completely shattered the central spider gear.
After contacting Toyota to source a new part and finding out they want $1200plus gst... I went to the local wrecking yarn. They had a fxxxed transfer off a similar model that they where able to remove the spider gear for me. $100.
Am now just awaiting new gaskets and seals to complete the rebuild. Should be back on the road in no time!

Talking with the local transmission shop about the issue, they have said this is issue is extremely rare and all the landcrusier transfers they have done, have all stripped the spines on the rear output sharf in the transfer. Mine all look as good as the day it left the shop!

Thanks for all the help lads
 
I have a similar issue 1991 lc cdl switch in dash locked I can drive where ever no noise no issues unlocked it will not move new Birfields new drive hubs removed third member cleaned and inspected can’t see any issues reinstalled same issue jacked up front end wheels off transfer case locked in drive neither drive shafts turn no noise transfer split 50/50 so front doesn’t move cause rear isn’t disengaged transfer case front drive shaft spins wide open noisy as can be in 3rd member area no axles turn at all could there possibly be stripped spider gears I’m fixin to pull unit apart again and inspect 3rd member again but any help or info would be great
 
You must log in or register to reply here.

Share this page

Back
Top Bottom