Transfer Case Rebuild - Pointers or Writeups?

[coultl]

Hi All, I have a groan/rumble when coasting at 55mph and higher. It’s worse when I’m out of gear. I suspected the transfer case, got under the car and pulled on the driveshaft…and immediately saw that there was play. Ha, that didn’t take long to diagnose. The output shaft that connects to the rear drive shaft has about 2 - 3mm of play. I guess that bearing is in pretty bad shape. I’m surprised it’s not making more noise and surprised it’s not leaking.

I did a search and didn’t find much in the forum. Are there any good writeups on the t-case rebuild? Any pointers from the group? I’m thinking I’ll get the kit from Cruiser Outfitters, but open to any leads on where to get the parts. Any good “while I’m in there” to do? The clutch is way overdue so I might do that and the rear main seal at the same time.

Thanks in advance for any help!

 

[cruisermatt]

Have you considered the factory service manual? It has literal instructions written by the folks who built your truck.

 

[coultl]

Yup, have the manual and use it for everything. Much better than most FSMs. That’s said, there’s usually some very valuable advice from those who have done the job before that you don’t find in the FSM. Also nice to get that wisdom recorded in a forum and not lost.

 

[BurntToast]

 

[Eurasiaoverland]

Transfer rebuild is pretty straightforward, you can do everything up to removing the transfer input gear from the transmission output shaft with a socket set and basic tools. The FSM is good (apart from some incorrect indications for which bolts to put thread sealer on). If yours is a manual then you may well find the brass bushings in the transfer output shaft gears are worn. You can replace the gear as a whole, but you can also buy the bushing, press it in and have it machined to size. That's the only step I can think of which is not in the FSM.

The above video is good, but if I remember correctly, they do not set the output shaft bearing pre-load, which is covered in the FSM.

 

[coultl]

Yes, it’s a manual. So helpful. Thank you!

Also, the video above is gold. I found a few others that were very incomplete when I looked. Thanks!

 

[cruiserpilot]

Sit down with a 6 pack and read this. It’s got it all.

some h55f and split case tech

there have been sooooo many threads on here about which split case to use on the back of an h55f and there's a lot of mis-information and lack of info out there. so let's try to clear this mess up a little. first off, i highly recommend to my friends and customers that they buy a new...

forum.ih8mud.com

 

[coultl]

Not sure how I didn't find this thread. Amazing. Thank you.

 

[cruiserpilot]

Not sure how I didn't find this thread. Amazing. Thank you.

Yup, I've done 3 rebuilds now since I read that. It's a Bible. It should be a sticky somewhere for everyone.
Hey @woody - what do you think, can we save this somewhere a bit more accessible?

 

[TheElegantFox]

Sounds like you definitely do need to check out that transfer case, based on the play.

Do check over your exhaust facing heat shields while you're down there, that turned out to be the source of my noise: FJ62 A440F Transfer case has bum solenoid and sounds like a loose slinging saw blade? - https://forum.ih8mud.com/threads/fj62-a440f-transfer-case-has-bum-solenoid-and-sounds-like-a-loose-slinging-saw-blade.1339625/#post-15523848


I also found this video when I was researching transfer case rebuilds:

 

[woody]

Yup, I've done 3 rebuilds now since I read that. It's a Bible. It should be a sticky somewhere for everyone.
Hey @woody - what do you think, can we save this somewhere a bit more accessible?

You mean, like the FAQ sticky'd at the top of most Tech sections?

No one reads directions...

 

[cruiserpilot]

You mean, like the FAQ sticky'd at the top of most Tech sections?

No one reads directions...

I can't find it at the top of the 60 section in the FAQ's. By a different name? I've been here for a long time,
search for it every time.

 

[rfj62]

When rebuilding the t-case on a 1990 FJ62 with an A440F, should I put any FIPG (red or black) on the o-ring between the bearing and the front T-case half?

 

[Eurasiaoverland]

When rebuilding the t-case on a 1990 FJ62 with an A440F, should I put any FIPG (red or black) on the o-ring between the bearing and the front T-case half?

View attachment 3780918

No. FIPG fills gaps between hard surfaces. O-rings are seals in themselves.

 

[rfj62]

No. FIPG fills gaps between hard surfaces. O-rings are seals in themselves.

Thanks, I appreciate it.

 

[rfj62]

Rebuilding my transfer case still.. Installed the rear output shaft with the High/Low shift fork. That gear assembly seems to not match up perfectly, slightly out toward the rear. Is that acceptable or is there something off? The gears all rotate smoothly. 1990 FJ62 stock T-case/transmission.

TIA Jeff

View attachment 3792339