Transfer Case slight carnage..... (2 Viewers)

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cc93cruiser

cc93cruiser

CRUZAHEAD
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Hayward, Ca.
Drained the transfer case gear oil on a new to us 1993 80 and found some nice size pieces of thin metal...metal apperas to have been there for awhile as its been all chewed up by the gears in the case.. All gears, bearings, everything appears intact... I took apart the rear housing and the center transfer case piece to get to center diff, all appear to be in good working order... Only thing that looks odd is a oil tube/pipe that is located in the center transfer case piece..It's just kinda hanging there all loose... Maybe a thin piece of sheet metal was holding it into place and brke off and got chewed up? Here are pics and oil tube and where all the metal fragments were found....Also 2 or 3 pieces actually have like a snall swivel of some type...Again, this metal is not from gears or bearings... Thin metal...

20161104_182129.webp


20161104_182145.webp


20161104_182255.webp


20161104_182229.webp
 
The 3rd and 4th pic shows the oil pipe... i can move this pipe easily.. The oil inlet pipe is right behind the oil strainer
 
The ball bearings in the transfer case are way bigger than these fragments.. The pic might be a bit deceptive, all these fragments fit in the inside palm if my hand.. The biggest pieces in the pic are no bigger than 1/2".. Plus those round bits on the last pic actually swivel around the piece of metal?? Stumped! Unless there had been work done to T C before and they didn't remove all the broken pieces.. But these pieces don't even look like they belong in the TC..
 
Those are definitely bearing cage parts. The swivel I think you are talking about is where one side is riveted to the other.

I forget exactly how it's retained, but the tube is just the xfer case oil pump pickup tube. There is supposed to be a sheet metal cover over the loose end with screws that go into the threaded holes.. not sure if there was originally some kind of filter media in there.. but the parts in the bottom of your case don't seem like they came from that cover. Second pic in this post: Converting HF2AV Transfer Case into Part Time Transfer Case

I'd guess your case ate a bearing at some point and whoever rebuilt it is as inept as the average shop mechanic, and didn't clean out the swarf or put the case back together correctly including that cover.
 
I am starting to think this is what happend... I do have a new ball bearing in box and I compared that to the fragments and can see how the gears must have flatend most of the round rivets and the kinda do resemble them.. There are no ball bearings and no other pieces.. Most of these pieces were by the oil pump strainer so whoever must have worked on this overlooked this pieces and left them in there.. The ball bearing in the rear housing is intact, just go to check the front one and I think I am good to go...
 
Does the 93-97 viscous coupler ABS transfer case have a roller bearing at the front Output shaft like the rear housing Output shaft? I just took apart a transfer case from a 1992 80 a non-ABS w/o viscous coupler and thr front output shaft had a sealed type bearing along with a ball bearing in the rear output shaft... Trying to figure out where my metal ftagments came from in my original post..

First I noticed that if there is a ball bearing in the front output shaft, I think its virtually impossible for these fragments to find there way into the center and rear cases because the front output shaft along with the gears/tappered bearings pretty much seal the area from the front output shaft to the center piece of transfer case... And eas thinking that if thesr fragments are from a ball bearing it has to be from the rear output shaft since i know there is ine in there..... please any advice.... Not home so I can't see in my FSM, plus you can't see if it's a tappered or ball bearing in FSM diagram...
 
bloc said:
Those are definitely bearing cage parts. The swivel I think you are talking about is where one side is riveted to the other.

I forget exactly how it's retained, but the tube is just the xfer case oil pump pickup tube. There is supposed to be a sheet metal cover over the loose end with screws that go into the threaded holes.. not sure if there was originally some kind of filter media in there..
Click to expand...
The cover was removed by me, it was held on by 2 10mm bolts.. It's the oil strainer and yes there is like a wire mesh in it.. Only thing I am trying to figure out now is if the fragments were caused by the rear output ball bearing or the front output bearing.. The front output seems like there is no way to get metal pieces from the front to the center/rear section as mentioned on my above post. Plus I think the front bearing is a sealed ball bearing. Thinking it came from the rear output at one point. Not sure if I should drop the TC or not, wish I knew how the front output bearing looked liked. As mentioned before, I took apart 1992 TC and it had a sealed type ball bearing from NACHI/Japan in the front output shaft.. Just don't know if they 91-92 TC differs from the ABS 93-97 TC's as far as bearing type goes....
 
cc93cruiser said:
Is this the front output shaft bearing.. OEM part number anyone? The one I took off from 92 TC looks exactly like this one, just different brand NACHI/Japan.

Timken® 208S - Front Transfer Case Output Shaft Bearing
Click to expand...

Keep in mind that if a bearing failed it'll frag those dust shields on the bearing very easily.. then letting the balls and chunks of bearing cage into the housing even if it was initially a sealed bearing.

Not that this means it's definitely from the front bearing.. just that it being sealed doesn't rule it out.

Also, since that area is where the xfer oil pump draws oil, the parts could have come from far away in the case originally. But.. if there are things in the way that would act as baffles I'd expect the parts to get caught on those before flowing to the pump intake.

Either way.. if the case runs ok now, and the bearings you can get to seem ok, no play in anything, everything runs smooth.. I'd just clean it out well and run it. MAYBE take apart the oil pump (never done this before) if it's easy and check the condition inside..
 
I think toyota used 2 different bearings for the front output shaft... One is a sealed ball bearing and other is regular ball bearing... Part #'s I have
Timken 208s
OEM #
90363-40044 replaced by 90363-40083
(not sure if timken or koyo)
NACHI 6208z
 
Last edited:
Yeah, I understand about a sealed ball bearing still being able to fragment...After taking apart another TC I had laying around, to me it's impossible for the fragments to have passed through the front output shaft were there are 2 tappered bearings and shaft/gears and a TC center piece that pretty much seals the front output from the center section...To me if these parts are from a failed ball bearing, it had to come from the rear output ... There is bout 3/8" gap on the rear output housing from the sides of dust shield to TC housing where the visciuos coupler is seated and a 1" window where you can see the speedmeter gear and rear ball bearing ...Frags must have traveled thru here... The bearing there now is in great condition..... If there was a R&R in the past with this bearing, it puzzles me how someone could have missed these bits and pieces... I bought the rig a month ago and have driven it a handful of times.. Drove 150 miles from place I purchased it with no noises/problems etc....
 
Pic of Fragments may have traveled to Center section of Transfer Case.

Screenshot_2016-11-06-08-25-46.webp
 
*Question*
Do these sealed type bearings not need any gear oil to operate properly like the tappered bearings or nonsealed ball bearings ? I mean they are sealed, which means they they must have grease of its own inside of bearing? If the are sealed for a reason, does that mean that gear oil does not travel/ reach the areas that the sealed bearings are located? Just trying to make sense of why Mr. T would use a mixture of bearings (sealed vs nonsealed) in a gear box full of gear oil....
 
cc93cruiser said:
I think toyota used 2 different bearings for the front output shaft... One is a sealed ball bearing and other is regular ball bearing... Part #'s I have
Timken 208s
OEM #
90363-40044 replaced by 90363-40083
(not sure if timken or koyo)
NACHI 6208z
Click to expand...

True, went out to the garage to check.

20161106_085136.webp


20161106_085152.webp


How do you know they're sealed ball bearings?
 
Well, i don't but they sure seem like the are.. I mean mean the ball bearings are not exposed like these which is found in the rear housing
(ball bearing pic from internet)
comp_5209W_profile_400.webp
 
The picture looks like a bearing with shields which are different from one that has seals. The shield would allow gear lube to pass through.
 
Guess what? chicken butt!..
Looks like a did have a bad ball bearing from the gear driven directly from transmission output shaft.... I'll post up pics in a little bit....

20161107_084307.webp

Pressing out the gear with press
20161107_085704.webp

Taking off one of the 2 bearings
20161107_084411.webp

Now time to press in the rear ball bearing, then the Gear itself and lastly the last ball bearing.. Then back in the gear box....
20161107_092733.webp
 
Bearing behind this gear ( Red Arrow) was the one that fell apart. I am replacing both bearings for piece of mind.

Screenshot_2016-11-07-09-51-02.webp
 
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