Transfer case puller tool - what am i missing here?

[Vae Victus]

Worst news - it was very hard to remove. There is an obvious 1/32" groove in the spline. Bob at TPI said if there is a groove, you should consider a new transmission.

Anyone got opinions?

Yeah, that's a common problem and new replacement shafts are very expensive, since there is little call for them. ....

By the way, I would expect similar wear on the inner splines of the input gear, so look at that carefully.

What causes the groove?

Transfer case input gear being loose on the transmission output shaft.

The loose gear on the shaft causes the wear you are seeing.

A new gear on that shaft will make the new gear garbage in short order.

Hmm, so when I was reassembling and noted the slop in the high speed gear, I guess I found out why there is a groove in my shaft splines. Hopefully if I replace the spacer with one that is slightly thicker, it wil reduce the slop in the gear and stop the wear that was happening (or slow it down).

The slop is not because the shaft is too small, that tolerance is tight. The slop is along the shaft axis, and allows the gear and spacer to move too much between the bearing and the stop on the shaft.

Anyone concur with that conclusion?

Georg, how much are those spacers for the output shaft bearings from AA?

 

[orangefj45]

They're $10 each

 

[Vae Victus]

Here's a pic of two OEM thrust washers. If you look closely, you can see that the one on the left is chamfered quite a bit more on the inside edge.

Georg @ Valley Hybrids

Thanks for your help, photos and input! I'll check my OEMs first.

 

[Vae Victus]

Yeah, that's a common problem and new replacement shafts are very expensive, since there is little call for them. You can try to find a used tranny with a better shaft or advertise for a good shaft out of a trashed tranny. If you're willing to dump $800+ into it, SOR has the shaft and rebuild kit.

FYI,
OrangeFJ45 has the AdvancedAdapters Orion spline. AA sells them for $138 on their website, so I'm sure Georg has them for same or less. Fine or Course spline.

Will these work in an OEM Transfer Case - I think so.

 

[Vae Victus]

Here's a pic of two OEM thrust washers. If you look closely, you can see that the one on the left is chamfered quite a bit more on the inside edge.

Georg @ Valley Hybrids

Mine are looking exactly the same on both sides. Anyone disagree?




Side A



Side B

 

[Vae Victus]

Putting the spacer(s) on the shaft with the gear installed, without the bearing. The spacer bottoms out on the lip of the shaft. The gap isn't going smaller than 0.019/0.020.


Lip



Gap

So I do need those spacers Georg. Question is one or both?

 

[orangefj45]

Here's a tool we made years ago and still use today.

Georg @ Valley Hybrids

 

[orangefj45]

When I check the clearance on the thrust washers to the gears ....... Here's how I do it.
Put the output shaft in a vise. Clamp down on the splines, not the smooth portion of the shaft, especially not the bushing surface. Slide your gear on, then the thrust washer. Then use a piece of 1.5" tubing and push down on the washer with one hand, measure the free play with your other hand.
Using the piece of tubing will allow you to get a true measurement.
Beeper this for the other side/gear as well.
Hth
Georg @ Valley Hybrids

 

[orangefj45]

If you need the stepped washer(s), send me a pm and ill make it happen.

Georg @ Valley Hybrids

 

[Vae Victus]

If you need the stepped washer(s), send me a pm and ill make it happen.

Georg @ Valley Hybrids

Done. Check your in box.

 

[Vae Victus]

So, next question. I'm trying to drive in the extension housing shaft and gear, to the housing. But, if I'm looking at this correctly from Coolerman, I'm driving the shaft back out of the bearing before it seats.






If I drive it into the housing with the shaft, the shaft falls out of the bearing that I just drove in.

Coolerman shows it this way, in his tutorial 1/3 of the way down the page here.

 

[Vae Victus]

Here's a tool we made years ago and still use today.

Georg @ Valley Hybrids

What's this used for Georg?

Also, quick bump on question on the post above this one - am I trying to seat that shaft correctly in the extension housing?

 

[Poser]

If I drive it into the housing with the shaft, the shaft falls out of the bearing that I just drove in.

Then stop driving the bearing in by striking the shaft.


Use a punch and tap on the OUTER race of the roller bearing.

 

[Vae Victus]

Then stop driving the bearing in by striking the shaft.

Use a punch and tap on the OUTER race of the roller bearing.

Oh, Poser, you have such a way with words!

Thanks for the help.

 

[subzali]

What are the pros and cons of an Orion? I've seen it mentioned 100 times, but I've never researched it. What does one retail for?

Long and short of it is that it has a 3:1 or 4:1 gear reduction vs. your stock 2:1 (approx.) gear reduction. Also has a stronger cast iron case vs. the aluminum stock case. Not sure on retail. Starting at $1574.91 on AA's website:
http://www.advanceadapters.com/prod...sfer-case-for-toyota-land-cruisers-1963-1980/

 

[SteveH]

Reviving this thread - does anyone know what the puller tool shown in the Toyota manual is actually called? I am considering buying one (or renting) and short of showing them a picture of it, I can't describe it. Thanks!

 

[73FJ40]

From the 1975 manual: (just named "puller")