Transfer case shifter FJ40

[FJ40Jim]

Well, now all is back in place and the linkage is real smooth except I can see that steel shift rod won't go into the second position (the seat for the ball bearing). I think at this point the problem is in the transfer case which hasn't spun for a long time, does that make sense? Or else I just need to turn the engine on so I can put it in gear a bit and see if the shifter will slide.

Yes, try spinning the frt driveshaft by hand while a helper inside yanks the lever back into 4WD.

What are your thoughts on the internal rubber ring where the steel shift rod goes in? I didn't change it, nor the fibrous cork colored ring gasket that sits right above it. I noticed they were both a little damaged but....I crossed my fingers and used 'em anyways.

It will probably be fine. Leaks in that area are generally less a concern than keeping it lubed enough to prevent galvanic corrosion.

I'm thinking of just cutting a piece of metal or rubber myself for the bell housing. What do you think? Seems easy enough and no one can see it anyway!

I think the easiest thing is to call toyota, order the right piece, and snap it into place. But I'm weird that way.

This part:
31121-60021 Boot, clutch vent $20.86

 

[sproggy]

I finally got the transfer working and in fine shape. But I had to back track a bit. Turns out the problem was frozen up linkage just as everyone thought, in particular the piston that comes out of that little box with the four screws. I got it back on and the thing still wouldn't work and I was kind of down about it which I took out on the piston by slamming it with a hammer multiple times (thinking that the inside of the transfer was gunked up plus it just deserved to be smacked a bit)...didn't help anything. However, after a nights sleep I went back at it and what I found out was that the fork (circled in red in the attachment -fj40 transfer case diagram) that is attached to that piston and inserted into the transfer case was not sitting in the correct groove on the shaft (inside the transfer case). Note: before reassembling that piston take a look inside the transfer case to note how that fork fits onto the inside shaft and make sure to line them up.
Cheers, thanks for the help all....

 

[Downey]

4WD Shifter

I think that even if you get the later 4 speed bottom shifting chamber with longer shaft (shown in pdgbottle's photo above) the lower end of your shift lever will be too far outboard to make contact with the shift chamber shaft. EASY FIX: get a 12mm x 1.75 thread pitch by 50-60mm long allen head bolt, and two matching jam nuts. Allen head bolt must have a .700 to .710 head O.D.. Drill open existing hole in the bottom of the shift lever to .465". Now allen head bolt can get positioned into the .465" hole and into the slot in the shift chamber shaft, and can be adjusted inward or outward as needed, then jam nutted.