Transfer rebuild got held up by bushing

[Spanky Pete]

I pressed the low gear of the output shaft and the bushing has spun to where the oil passage hole in the bushing no longer lines up with either of the oil passage cutouts in the gear.

The wear on the bushing looks fine, but I believe that is because it hasn't been in 4-lo in forever.

I thought I might be able to press the bushing out and reuse it, pressed in so that it can get oil to it. But not having a press and using the BFH method, I think this thing is going to be torn up by the time I get it out.

The bad news: I just called Cdan and he said this part was not available as a service part and that I would need the low gear with the bushing already pressed in, however, this part is no longer available, and the last published price was something like $590.

So I guess I will try and track down a parts case. Can anybody educate me on what years interchange for the low gear? Mine is from a 5/85 case.

 

[lehiguy]

I pressed the low gear of the output shaft and the bushing has spun to where the oil passage hole in the bushing no longer lines up with either of the oil passage cutouts in the gear.

The wear on the bushing looks fine, but I believe that is because it hasn't been in 4-lo in forever.

I thought I might be able to press the bushing out and reuse it, pressed in so that it can get oil to it. But not having a press and using the BFH method, I think this thing is going to be torn up by the time I get it out.

The bad news: I just called Cdan and he said this part was not available as a service part and that I would need the low gear with the bushing already pressed in, however, this part is no longer available, and the last published price was something like $590.

So I guess I will try and track down a parts case. Can anybody educate me on what years interchange for the low gear? Mine is from a 5/85 case.

Sounds like its time to make a trip to a good machinist. Making a bushing should not be too hard.

 

[Spike Strip]

I see that bushing being available on trade-motion 90999-73089 But EPC only lists it for 80-82 ... Wonder if it'll work ?

Otherwise, it's 36204- 60041 which lists for $286 82-4/86 BJ, FJ60 4F

SOR or Cruiser Parts might have it used.

 

[2mbb]

Why not take the gear to a machine shop and have them press it out then back in again?

Or can you just drill a new hole i the bushing, through the oil passage in the gear?

I'm also not really understanding how the oil passage works. in an engine the oil is under pressure so it is pushed through the passages. In the transfer case, the gears sit in an oil bath (no pressure). In the FSM, the oil clearance is checked to be within spec. however, won't the oil passage let the oil out, leaving the busing unprotected?

 

[Spanky Pete]

Like mike suggested, I had a shop (Nappa) press it out, then press it back in the proper orientation. Cost: $10.50
Initially, it was not wanting to fit back on the output shaft, but a quick touch with a small hone, and it fits.

The oil clearance measurements in the fsm are for between the output gears and their respective bearings. It seams that these clearances allow the oil bath to get between the gear and bearing down to the shaft, the oil can then enter the groove cut into the gear, and via the bushing hole enter the runs cut into the bushing surface, feeding oil between bushing and shaft.

 

[2mbb]

The oil clearance measurements in the fsm are for between the output gears and their respective bearings. It seams that these clearances allow the oil bath to get between the gear and bearing down to the shaft, the oil can then enter the groove cut into the gear, and via the bushing hole enter the runs cut into the bushing surface, feeding oil between bushing and shaft.

That makes sense. I didn't realize the bearing was between the shaft and the bushing.

 

[Eurasiaoverland]

Like mike suggested, I had a shop (Nappa) press it out, then press it back in the proper orientation. Cost: $10.50
Initially, it was not wanting to fit back on the output shaft, but a quick touch with a small hone, and it fits.

The oil clearance measurements in the fsm are for between the output gears and their respective bearings. It seams that these clearances allow the oil bath to get between the gear and bearing down to the shaft, the oil can then enter the groove cut into the gear, and via the bushing hole enter the runs cut into the bushing surface, feeding oil between bushing and shaft.

I have been dealing with a transfer output shaft gear bushing recently and just wanted to correct what is written here, as I am quite sure that the premise is wrong.

Having looked at my old transfer output gears, and a brand new high-range output gear, I am certain that those two parallel cut-outs in the transfer gear are not related to oiling. They do not line up in any of the gears. There are no oil feed holes in the gear or the transfer output shaft, oiling is passive. The fact that the bushings have one oil hole while the gear has two machined slots is already indicative that they are not related.

Furthermore, I do not for a moment believe that the bushing would spin in the gear without seizing on the shaft or showing severe fretting. Having pressed various bushings in and out of these gears (it has been a bit of a learning curve!), I believe that those slots in the gear are in fact to keep the bushing in place. Each bushing I have pressed out shows a small (catch it with a nail size) corresponding ridge (formed during pressing in).

I would also not recommend re-using a bushing. I have found two Toyota bushings which fit and are still available, though neither is the same as the original. 90999-73079 is the closest (and cheaper of the two), maybe 1-2 mm narrower than the original. 90999-73089 is much wider and would need to be machined down maybe 5 mm before fitting (which I only found out after pressing it in).

Hope this might help someone who is wondering about the oiling hole. In short, I don't thonk it matters. I would be more inclined to align the edge of the diagonal oiling channel in the bushing to the cutouts in the thrust face of the gear.

Picture below of my brand new, genuine, high-range transfer output gear. Notice the oiling hole and the indication of that machined channel in the gear. Not aligned.

EO