OK, the transfer case in my 79 FJ40 is shot. I purchased a case from the same year 40. I'm in the process of taking out the case in the rig right now. I started going through the case I purchased and have a few questions. Sorry if any are too basic, this is my first.
a. If you aren't running the PTO am I correct that under the PTO cover plate, there is one gear, spacer, stake, and lock? Would the second gear in that area be for the PTO? I'm looking at the factory chassis and body repair manual and am a little confused.
b. Against what everybody is saying on the forum, I'm going to attempt to pull the case only. Am I missing anything? This is what I am planning on:
- remove ebrake cable
- remove front and rear drive shafts
- take off shift linkage (haven't looked at what this involves yet)
- remove back up light switch.
- put jack under trans for support.
- remove bolts on PTO cover (cone looking deal)
- remove bracket supporting tcase
- remove five bolts holding case to trans.
- 3 bolts along top.
- 2 inside inspection plate.
- remove nut holding on large gear and remove gear off shaft.
- slide transfer case off shaft without smashing self to death or losing any appendages using jack or some other anti-gravity device.
I'm going to take a bunch of pictures to document the process. I haven't found a really good write-up on the removal process of the stock tcase. Probably because it's so basic. Oh-well, I'll list whatever I come across in hopes of helping other first timers.
Are there any other seals or other things I should replace while I have it apart?
Any other tips / suggestions would be greatly appreciated!
a. If you aren't running the PTO am I correct that under the PTO cover plate, there is one gear, spacer, stake, and lock? Would the second gear in that area be for the PTO? I'm looking at the factory chassis and body repair manual and am a little confused.
b. Against what everybody is saying on the forum, I'm going to attempt to pull the case only. Am I missing anything? This is what I am planning on:
- remove ebrake cable
- remove front and rear drive shafts
- take off shift linkage (haven't looked at what this involves yet)
- remove back up light switch.
- put jack under trans for support.
- remove bolts on PTO cover (cone looking deal)
- remove bracket supporting tcase
- remove five bolts holding case to trans.
- 3 bolts along top.
- 2 inside inspection plate.
- remove nut holding on large gear and remove gear off shaft.
- slide transfer case off shaft without smashing self to death or losing any appendages using jack or some other anti-gravity device.
I'm going to take a bunch of pictures to document the process. I haven't found a really good write-up on the removal process of the stock tcase. Probably because it's so basic. Oh-well, I'll list whatever I come across in hopes of helping other first timers.
Are there any other seals or other things I should replace while I have it apart?
Any other tips / suggestions would be greatly appreciated!