Transmission and Transfer case removal. First time

[MoaByte]

Thought I'd share the journey.
First, we removed the shift boots. No biggie there.
Then the shifter. Simply push down the collar and twist counter clockwise. No tools needed. While you are in there, reach in and disconnect the two electrical quick connects.

Then we marked alignments on both end of both drive shafts. 1/2" drive ratchet with a 6" extension made that pretty easy on the TC side, same procedure for the diff side except you also need a 14 mm wrench.

Then unscrew the speedo cable and the ground strap from the body. Then we disconnected the battery.

Disconnecting the TC shift lever was a bit confusing, but it is only one nut and one cotter pin. Then wiggle it until it slides off.

 

[MoaByte]

First weird thing was gear oil pouring out of the TC when the rear drive shaft was removed. I don't remember that happening before.

Next, was the bolts holding the front driveshaft to the diff were figure tight. I have never removed this before so I was a bit surprised.

 

[MoaByte]

We got the 4 bolts loosened holding the Tranny to the bell housing loose with 1/2" breaker bar. A 1" extension helps on the upper passenger side. They have 17 mm heads. After breaking them loose, we switch to a 3/8 drive cordless ratchet. I love that tool!

 

[MoaByte]

Removed the clutch inspection cover. Then the 8 bolts that attach the tranny mounts. Supported the engine with a jack and block, then removed the cross member. Only broke one bolt.
Now I'm having a beer and getting ready to separate the mess and drop the trans.

 

[Godwin]

Removal - gravity is your friend.
Installation - gravity is your foe.

 

[MoaByte]

The garage bar crowd showed up. One beer led to two. It's not coming out tonight.

I'm contemplating drilling out the plate on the HB tranny jack and thinking about replacing all the motor mounts and the oil pan gasket. I wasn't going to, but damnit... While I'm in there. This really isn't that fun and as my daily, I don't want to do it again.

 

[ChaserFJ60]

The garage bar crowd showed up. One beer led to two. It's not coming out tonight.

I'm contemplating drilling out the plate on the HB tranny jack and thinking about replacing all the motor mounts and the oil pan gasket. I wasn't going to, but damnit... While I'm in there. This really isn't that fun and as my daily, I don't want to do it again.

Replacing the motor mounts can be done without removing the trans, I would recommend doing one at a time, My motor shifted pretty hard when I had two of the mounts out and it was a job to manipulate it back into the correct position. Make sure you remove the transmission body plate inside your cab. I made that mistake and it made for an... aggressive transmission removal. The bolts are hidden under your carpet.

 

[Gimme a 60]

The hardest thing I have ever done on a Toyota is a head gasket on a 3.0 pickup. My transfer case needed to be rebuilt on my landcrusier and I took it into a mechanic because the Haynes rebuild manual won’t show you how to rebuild it because it’s “beyond the knowledge of the book and needs to be done by a professional”. Very very expensive and wish I would have just winged it myself.

 

[MoaByte]

Replacing the motor mounts can be done without removing the trans, I would recommend doing one at a time, My motor shifted pretty hard when I had two of the mounts out and it was a job to manipulate it back into the correct position. Make sure you remove the transmission body plate inside your cab. I made that mistake and it made for an... aggressive transmission removal. The bolts are hidden under your carpet.

Trans plate under the carpet? Are you referring to the plate that the shift boots bolt to?

I cut the Kilmatt to not interfere if I should have to do so, but I really don't wanna pull the seats and carpet if I can avoid it.

 

[cps432]

The garage bar crowd showed up. One beer led to two. It's not coming out tonight.

I'm contemplating drilling out the plate on the HB tranny jack and thinking about replacing all the motor mounts and the oil pan gasket. I wasn't going to, but damnit... While I'm in there. This really isn't that fun and as my daily, I don't want to do it again.

You don’t need to drill out the plate. Just cut a piece of 1/2” plywood to hang over and drill out the plywood to mount to the transmission mount. Bolt the plywood to the jack plate with the hardware HF supplies.

 

[MoaByte]

The lessons I've learned from mechanics are:

1.) Take your time to understand the situation.

2.)Tools are usually cheaper than labor. A man is only worth his tools and ability to use them. You can make special tools if you have the right tools. Cheap tools are sacrificial, good tools are sacred. Clean them and put them away every day even if the job isn't done. If you borrowed a tool, return it promptly and clean and toss in a 6-pck or more.

3.) If you have eyes to see and ears to hear... Just kidding, that's the bible. But give it your best shot. See rule #1,

3.) Parts are cheaper if YOU source them. OEM or the next best thing for that vehicle.. it can ba a tough call because of money, but time counts too.. OEM unless you don't mind doing it again.

4). Follow the FSM. Haynes and Chilton's suck. Read it again and again. YouTube can be your best friend.

5.) Expect to fix more "while you are in there". Every project will cost more and take longer, unless you are stupid, then it will take even more money and time. If you can't afford to do it right the first time, you can't afford do it twice. If you have to do it twice, I hope you learned something.

6.) If you have help, feed them, maybe offer beer at the end of the day. Be prepared to help them when their s*** breaks down.

7). If it fails, you will have firsthand knowledge why. Sure beats calling your mechanic at 2:00 am.

8.). It's your truck. If it's vintage and your DD. It's your responsibility. Tire mounting and balancing or pumping gas are one thing, but changing oil or tuning, at least require your full attention to what they do. Bodywork etc. If you hire a pro, learn what Grace they bestowed on your machine.

10.). I dunno yet. What's 10?

 

[ChaserFJ60]

Trans plate under the carpet? Are you referring to the plate that the shift boots bolt to?

I cut the Kilmatt to not interfere if I should have to do so, but I really don't wanna pull the seats and carpet if I can avoid it.

I would 110% take it out, There is no other way. You can get the trans in and out but you will have to significantly bend the plate to do so.

 

[cps432]

The lessons I've learned from mechanics are:

1.) Take your time to understand the situation.

2.)Tools are usually cheaper than labor. A man is only worth his tools and ability to use them. You can make special tools if you have the right tools. Cheap tools are sacrificial, good tools are sacred. Clean them and put them away every day even if the job isn't done. If you borrowed a tool, return it promptly and clean and toss in a 6-pck or more.

3.) If you have eyes to see and ears to hear... Just kidding, that's the bible. But give it your best shot. See rule #1,

3.) Parts are cheaper if YOU source them. OEM or the next best thing for that vehicle.. it can ba a tough call because of money, but time counts too.. OEM unless you don't mind doing it again.

4). Follow the FSM. Haynes and Chilton's suck. Read it again and again. YouTube can be your best friend.

5.) Expect to fix more "while you are in there". Every project will cost more and take longer, unless you are stupid, then it will take even more money and time. If you can't afford to do it right the first time, you can't afford do it twice. If you have to do it twice, I hope you learned something.

6.) If you have help, feed them, maybe offer beer at the end of the day. Be prepared to help them when their s*** breaks down.

7). If it fails, you will have firsthand knowledge why. Sure beats calling your mechanic at 2:00 am.

8.). It's your truck. If it's vintage and your DD. It's your responsibility. Tire mounting and balancing or pumping gas are one thing, but changing oil or tuning, at least require your full attention to what they do. Bodywork etc. If you hire a pro, learn what Grace they bestowed on your machine.

10.). I dunno yet. What's 10?

10. Don’t drink ten till after you put away the tools.

 

[MoaByte]

Well, that was easy. Supported the engine with a bottle jack and 2x4, set up the tranny jack, wiggled it back and it was out.

 

[MoaByte]

Now here is my dilemma. Nobody in Moab resurfaces flywheels. Second, look at those cracks!

 

[4Cruisers]

How soon do you need one? I had this one ready for my '84 FJ60, but I sold the vehicle in January. It can't take too long to ship it to you from northern New Mexico.

 

[4Cruisers]

PM me if interested. I'm heading to the Post Office this afternoon to mail a package to another MUD member.

 

[dbbowen]

You dont have an Oreilley near you do you? usually theres one in your town thats bigger than the other that serves as the hub for the smaller stores. If you find that shop theyll usually have a machine to resurface rotors and flywheels. Oreilley did my 22re flywheel some years back.

- First weird thing was gear oil pouring out of the TC when the rear drive shaft was removed. I don't remember that happening before.

Depending on how much is "pouring" its either a rear output shaft seal or theres no sealant on the splines of the rear output shaft.

As far as the Tcase removal and rebuild, everything you need is in these two videos. Its pretty dang easy to do, even up under the truck. Your arms just get tired from holding the heavy parts after a while.

 

[cps432]

There isn’t an oreilly that has a lathe out there?

 

[OSS]

Well, that was easy.

Pulling out is always easy. It’s the insertion that can be tricky.