Transfer Case Rebuild & Modification (Low & High Range Gears & Part Time 4wd Kit) (1 Viewer)

[OEMGUY0720]

Got the part numbers from the video description Thursday evening and went ahead ordered them from Partsouq.com to get the ball rolling on this project:
- Front Seal: 90311-50014
- Front Bearing: 90363-40083
- Rear Seal: 90311-58008
- Rear Bearing: 90363-50005
- FIPG: 00295-01281
- Transmission output seal: 90311-48016 (got this from George when I called cruiser brothers Wednesday afternoon).

This round cover is a bit stubborn, already removed the three 10mm bolts and it this won’t come off, any other suggestion you can share?

From the part 1 video that George did, the specific plate they were working on had thread on it and he used three (3) M8x1.25 bolts which was used to raise the plate after rotating it a bit same as like popping out a drum brake if it’s stuck. However in my case, that hole is smooth and doesn’t have existing thread to use an M8x1.25 bolt.

Stumped at this point. Any recommendations is greatly appreciated.

 

[GTV]

Got the part numbers from the video description Thursday evening and went ahead ordered them from Partsouq.com to get the ball rolling on this project:
- Front Seal: 90311-50014
- Front Bearing: 90363-40083
- Rear Seal: 90311-58008
- Rear Bearing: 90363-50005
- FIPG: 00295-01281
- Transmission output seal: 90311-48016 (got this from George when I called cruiser brothers Wednesday afternoon).

This round cover is a bit stubborn, already removed the three 10mm bolts and it this won’t come off, any other suggestion you can share?
View attachment 3549616

From the part 1 video that George did, the specific plate they were working on had thread on it and he used three (3) M8x1.25 bolts which was used to raise the plate after rotating it a bit same as like popping out a drum brake if it’s stuck. However in my case, that hole is smooth and doesn’t have existing thread to use an M8x1.25 bolt.
View attachment 3549849
Stumped at this point. Any recommendations is greatly appreciated.

How is the project going? I'm itching to start the same job soon but want to have minimal downtime and be done right. I imagine you got high and low gears? Where did you get them from?

 

[OEMGUY0720]

How is the project going? I'm itching to start the same job soon but want to have minimal downtime and be done right. I imagine you got high and low gears? Where did you get them from?

I just realized I was not able to respond to your message until now. During the time I worked on my tcase done I was pressed with time because we’re going out on a trip and the LX was the designated vehicle to use so I didn’t do the 10% UD for the High Range. But from that time to now I already did two more TCase rebuilds for a couple of buddies. There were a few hiccups here in there but nothing that can’t be figured out. Overall they are now getting an additional 3MPG improvement (both 4-speed auto trans) and less gear-hunting for their ATe during uphills on interstate hiways. I will be doing mine probably after Thanksgiving. How is yours so far?

 

[GTV]

I just realized I was not able to respond to your message until now. During the time I worked on my tcase done I was pressed with time because we’re going out on a trip and the LX was the designated vehicle to use so I didn’t do the 10% UD for the High Range. But from that time to now I already did two more TCase rebuilds for a couple of buddies. There were a few hiccups here in there but nothing that can’t be figured out. Overall they are now getting an additional 3MPG improvement (both 4-speed auto trans) and less gear-hunting for their ATe during uphills on interstate hiways. I will be doing mine probably after Thanksgiving. How is yours so far?

They've been great! I'm within 98.5% of stock gearing in high, it drives like it has 31.5" tires instead of the factory 31". So pretty much like stock, which is great. And the low gear is really, really good now. So much better to descend with and it just crawls up everything. I did notice a bit of gear whine at first but that went away quickly, they're dead quiet now. I made a lot of changes around the same time so I can't fairly compare my mileage figures but my average since has been in the high 14's (with a RTT, awning, bikes, + usually 2 people loaded for adventure). I'm super happy with how the combo has worked out.

 

[OEMGUY0720]

They've been great! I'm within 98.5% of stock gearing in high, it drives like it has 31.5" tires instead of the factory 31". So pretty much like stock, which is great. And the low gear is really, really good now. So much better to descend with and it just crawls up everything. I did notice a bit of gear whine at first but that went away quickly, they're dead quiet now. I made a lot of changes around the same time so I can't fairly compare my mileage figures but my average since has been in the high 14's (with a RTT, awning, bikes, + usually 2 people loaded for adventure). I'm super happy with how the combo has worked out.

That’s good to know. I haven’t seen/read an actual field report for 5-speed and/or VVTi 100 series post-UD 10% high range install so this is good information. When I did the road testing for the 4-speed, I immediately noticed how the acceleration was better from 1st to 2nd and 2nd to 3rd gears. Running 35x12.5s, even if its VVTi I can feel the loss of agility on the lower gears. Also, to get an additional 3 maybe 4MPG is a huge win (that’s 30% fuel consumption improvement).

 

[Gerrha]

PART 2

Hello There,
With perfect timing, I discovered this series of videos, and they are so helpful. I am in the middle of rebuilding my own HF2AV with the part-time conversion. Georg makes those snap rings look so easy, but in my limited experience, each one is a little terror and with all of them in this case, I have been terrorized a lot lately.

So far, I have just one question I hope you guys can help with. At the 14:37 minute point in Part-2, Georg discusses a sleeve bushing for the side gear that is about 3/8" thick and is pressed into the case. He mentions a pilot bearing puller can be used to remove it for replacement. The problem is, I cannot find that bushing an any part list or diagram. Would you happen to know the part number?

 

[Timmy65]

Great video Tim. Your content is excellent.

Hello There,
With perfect timing, I discovered this series of videos, and they are so helpful. I am in the middle of rebuilding my own HF2AV with the part-time conversion. Georg makes those snap rings look so easy, but in my limited experience, each one is a little terror and with all of them in this case, I have been terrorized a lot lately.

So far, I have just one question I hope you guys can help with. At the 14:37 minute point in Part-2, Georg discusses a sleeve bushing for the side gear that is about 3/8" thick and is pressed into the case. He mentions a pilot bearing puller can be used to remove it for replacement. The problem is, I cannot find that bushing an any part list or diagram. Would you happen to know the part number?

I don't know that part number. I would call Valley Hybrids or Cruiser Brothers and I'm sure they can get that bushing for you.

 

[Gerrha]

I don't know that part number. I would call Valley Hybrids or Cruiser Brothers and I'm sure they can get that bushing for you.

Will do, thanks!