transfer seal replacement

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Joined
Sep 9, 2004
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Location
Richmond B.C.
Well looks like I am another one with the fluid running from one box to another,unfortunatelty it is from the tranny to the transfer case and I do not believe the hose set up will work in this case.
By doing the job under the truck without removing the tranny and transfer case as a whole but splitting the transfer case ,will the gear clusters,shift forks etc come out with the removal of the rear case or are some parts going to be staying in the front case and some in the rear.Looking at the break down,hopefully everything comes out with the rear case removal or its going to be a hard time getting the forks installed correctly.
Any tips would GREATLY be appreciated....
Thanks James....
 
My memory is a bit hazy, but...

You need a good impact wrench to get the nut holding the input gear and bearing. In a 40 the stuff gets in the way and I needed long extensions so the impact wrench was behind the axle, but then I have an NV4500 which is much longer than an H55f.

It just gets a little tricky installing the output gear cluster while keeping the hi-lo fork in the correct position. A friend, GF or wife to help this part of the install would be good. Try to work on a bright surface instead of dirt so a lot of light bounces off the floor and you can see what you are doing.

The parts in front of the output bearing retainer can stay. Grease doesn't hold the idler shaft bushings well, use disk brake quieting spray to stick them in place.

One tip, when the case is off this is a good time to convert the spring loaded case breather on top so it accepts a hose.

Dave
 
I have done the transfer seal on my '60 with the tranny/transfer in the truck. If that is the only work that you need to do and you don't have access to tranny jacks and all that good stuff then in my opinion it's faster to do it in the truck.
Everything comes out with the rear half of the split case. The hard parts, as I remember, is the idler and those thrust washers as well as getting the output gears to all line up.
 
with a split case in the truck is the easiest.
for the thrust washers clean the case well and put a very thin layer of silicone on the case behind where the washer goes, insert the shaft and let dry. do he same with the front washer and you are good to go, once you have done a few then the job only takes about 2 hours at the max...
the first time have a manual handy and as Stoney mentioned the shifter can be a bear to get back in properly. i have often wondered why Toyota didn't design the notch to the top instead of the bottom...
cheers
 

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