Transfer Case Rebuild with new gears (6 Viewers)

[thetoyotaman]

The turtle build turns attention to the transfer case. Rebuilding with new bearings, low range transfer case gears, and high range underdrive gears.

As I’ve gone along with this project it’s been fun to wrench with Cruiser friends. Thanks @JohnnyOshow22!

We started with a tear down of the case.

 

[LC4LIFE]

The turtle build turns attention to the transfer case. Rebuilding with new bearings, low range transfer case gears, and high range underdrive gears.

As I’ve gone along with this project it’s been fun to wrench with Cruiser friends. Thanks @JohnnyOshow22!

We started with a tear down of the case.

View attachment 1823895

Why the new bearings? I have been told they rarely need to be replaced unless the case has been run very low on oil. Also interested to hear your thoughts on under drive noise once you're all done.

 

[thetoyotaman]

Notice the output shaft oil sludge. We pulled it apart and rear bearing slightly rough and loose causing seal failure. My experience over the years is 300k is a good time to change bearings. The bearings look good in general but loosening up. I don’t want my new gears walking at all.

 

[mudgudgeon]

For the amount of effort to pull the t case and strip it, putting fresh bearings in while you're in there is a no brainer to me, especially with 300k on them.

 

[thetoyotaman]

That’s really exactly what I was thinking.

 

[thetoyotaman]

There’s 4 sections of the housing.

 

[thetoyotaman]

Each section can be pulled off the back of the tranny one at a time with simple bolt removal and a rubber mallet. Removing the big cluster comes out by hand after removing a torx bolt and shift rod indention ball. The shafts come out of the housings with snap ring removal and a hammer with block of wood. The bearings will require a bearing splitter and press. Next is to remove the sensors and small parts for case cleaning.

 

[thetoyotaman]

Good video on rear housing bearing and seal replacement.



Marlin gear install instructions

Our new 80 & 100-series Land Cruiser Low Range Gear Kit Install

 

[thetoyotaman]

Speaking of replacing bearings, I’m looking at this extension housing bearing and haven’t found it in my FSM. Can I just remove the housing and replace it?

 

[baldilocks]

What is the under drive ratio?

 

[thetoyotaman]

10% underdrive high range.

 

[baldilocks]

10% underdrive high range.

Is this instead of ring and pinion ratio change?

 

[thetoyotaman]

Yes

 

[thetoyotaman]

Accidentally busted a sensor with my rubber mallet separating the case. Anyone know the part number?

 

[thetoyotaman]

Also previous owner repair of a clamp over the speed sensor. Anyone seen this before? Anyone know a part number for this? Thanks!

 

[Monty231]

Accidentally busted a sensor with my rubber mallet separating the case. Anyone know the part number? View attachment 1826270

I think that's the same as the CDL indicator switch that goes bad from time to time. Which is used in a few other places on the 80 and is a NSS/back-up light switch on other cars.

Toyota part no. 84222-12010

Napa NS6421

 

[Tools R Us]

Accidentally busted a sensor with my rubber mallet separating the case. Anyone know the part number? View attachment 1826270

Ask for a backup light switch for a 2000 5spd Tacoma, like: BECK/ARNLEY 2011788

 

[Heckraiser]

subscribed. this job may be in my not-too-distant future :/

 

[Shoredreamer]

My gears showed up from Cruiser Outfitters and I’m picking up a spare t case today to do this job in my garage, taking my time, with hopefully no stress. Actually looks fun if it all goes right haha!

 

[DanMedeiros]

I will be tagging along with @Shoredreamer Never tried anything like this, hoping I avoid blowing up my Tcase lol