Transfer Case?

[JLight]

Couple questions.

#1 - The front output shaft bearing is gone. I mean really missing. It looks like the races are still there but the shaft is all afloat. Can this bearing be replaced from outside the cases?

#2 - How hard is it to drop the Transfer case if I have to? Do I need to pull the tranny too? Any tips?

 

[cruiser_guy]

You'll need to pull the transfer to replace the bearing. It is possible to pull the transfer apart without pulling the tranny. You'll be working on your back but I've done it and will do it again if it is only transfer work that needs doing. The transfer can only be taken out by taking it apart while still attached to the tranny (you cannot simply remove the transfer on its own as a unit).

 

[JLight]

So I just start at the back and start taking it off in sections?

 

[dd113]

So I just start at the back and start taking it off in sections?

You really should start with a FSM. Buy it first. Then ask lots o questions. Nothing hard about it.

 

[Cruisergreg]

You really should start with a FSM. Buy it first. Then ask lots o questions. Nothing hard about it.

And pay close attention to how things come apart, things tend to fall out as the case is split.

One other gem: Be very careful to reattach the outer portion of the case as parallel to the shaft as possible. There is an oil slinger in there that can be bent and then will impact the casting ribs making a disturbng sound when driving. Don't ask me how I know this...

 

[Satamax]

Hi everybody!

Well, my third post here! I introduce myself quickly, i'm French, my name is Max, and i drive an 87 HJ61. I'm jumping on this discussion, cos i'm having Tcase problems. Cruisergreg, could you describe the noise it makes please? I haven't disassembled the Tcase, but i have lots of noisecomming from it! Guys, i've got the french equivalent of a haynes manual, it's clear enough about tcase removal, by gettin the GB out too. That would be verry nice if you could explain how to get the Tcase out without teh GB! I was wondering if the Don, Amway's tool http://www.ih8mud.com/tech/tcremove1.php wasn' meant to do that, pulling the Tcase without taking it apart ?! By the way, i think i have a split Tcase, but i don't know what number reffers to it on the constructor ID plate. I have an H55F gearbox. KO55 LSD. there's two numbers which i don't know what they are: /147/ and FB11 wouldn't the FB11 be the Tcase?
To descrive the problem, i case someone can diagnose it, because they've heard/seen it before! Basicaly, it goes, rrrrrrrrr clac clac,rrrrrrr clac, may i could describe it better, teh clac my sound more like cronk. I don't know! And if i put the Tcase in neutral, you can hear something going tchink tchink tchink, it realy has a ring to it! Like when you hit a big wrench with a hammer. But that only happens if i'm in fourth or fifth, i think the other three speeds don't make the Tcase turn fast enough for it to make too much noise.

Well, thanks a lot for reading.

Best regards.

Max.

 

[cruiser_guy]

So I just start at the back and start taking it off in sections?

That's basically it but as others have said a FSM is EXTREMELY helpful. As for the later post, the transfer case removal tool is for the older single peice case that was discontinued in North America with the last of the 1979 models. The split case MUST be disassembled to remove it from the transmission. There is NO other was as mounting bolts are located inside the transfer.

 

[Satamax]

Thanks a lot cruiser guy! I think since the weather is good, i'll go underneath today! No garage or anything, and i've got to do it before the snow!

Best regards.

Max.

 

[JLight]

You really should start with a FSM. Buy it first. Then ask lots o questions. Nothing hard about it.

I downloaded the one from birfield for an 84 but it doesn't list the FJ60 specifically. I've read through it a few times and it seems easy enough. I'm assuming mine will be the same.

I don't think I'm going to do it though. I think this one's getting parted. I found an 84 really cheap that is running and in better shape so I think I'll go that route. If you need anything for a 60 I've got a complete one with 120,000 miles. Pretty rusty but everything is there.

 

[Satamax]

Hi everybody!

Thanks a lot for your replies! Here's where i stand now! I know where the noise was comming from!

The iddler's shaft and bearing are extremely worn out, and there was some seroius play in the back's output shaft bearing. The iddler's shaft might have one mm missing under the bearing's races! Anybody has an idea of where this might have come from, besides the seroius wear of the parts? By the way, the bolt on the primary arbor wasn't tigntened against the bearing, normal????

Jlight, you might want to have a look there,http://perso.wanadoo.fr/adherence.4x4/serie6_chassis.htm 60 series chassis, and tranys etc! About two or three megs pdf file!

Thanks a lot and best regards.

Max.

 

[giacomo]

Hi everybody

I resume this discussion after many years as I am in the same situation
so I would like to know if it is only possible to remove the transfer from the gearbox without removing both units together
thank you

Giacomo

 

[g-man]

You can pull the back half off the transfer case while it is in the truck. It's going to be a tight work space but it's certainly possible. Most will remove the trans/t'case as one unit simply for ease of rebuilding. Also keeps things cleaner

 

[giacomo]

Thank you g-man
so you can rebuild the transfer without detaching it from the gearbox ?
Giacomo

 

[g-man]

Yes but not the preferred way. You need to split the case, remove the rear 1/2 of the case in order to access the bolts that hold the front 1/2 case to the transmission. download the 84 chassis and body FSM and read over the TF section. Easy to replace input and output shaft seals while on the truck.

Go here: For Sale - 40, 50, 60, and 80 series FSM for a hell of a price.

and get the FSM

 

[FJ60Seth]

I have a new 38mm idler shaft, bearings, o-rings and thrust washers. Vendor sent me the wrong kit (mine is 34mm) and didn’t want these back. Free to a good home. PayPal me $8.00 and I’ll ship them to any USPS zip code in a small flat rate box.

 

[FJ60Seth]

Gone to a new home.