Transmission/Transfer Case rebuild or…

[AKPoser]

74 with a 4 speed-
I have the f1.5 motor, trans, transfer out currently and getting the block and head machined to rebuild.
My question: Should I spend time and money on rebuilding or just gasket the transmission and Transfer case (T&T).

Im not sure if T&T needs a full rebuild due to only getting the ol basket case running to find the the bottom end of the f1.5 needs rebuilt. In the 4-5 miles I did drive it everything seemed smooth and no noticeable noises that I could hear at a top speed of 25-35 mph. Shifts smooth in 2 wheel drive and 4. Thoughts and recommendations for T&T parts?

 

[Green Bean]

It will never be any easier than now while it is out. Plus, it seems like it would be a really great feeling to go back with essentially a totally fresh drive train.
Just my 2 cents.

 

[Skreddy]

Will you be rebuilding or sending out? The 4 speed is, um, difficult to tear down completely. I believe there are some special service tools to get the bearings out.

T-Case isn’t difficult at all.

 

[AKPoser]

Will you be rebuilding or sending out? The 4 speed is, um, difficult to tear down completely. I believe there are some special service tools to get the bearings out.

T-Case isn’t difficult at all.

Until your message I was planning on doing in house. I wasn’t aware of the special service tools besides a standard bearing puller. Maybe I could take to a local shop when I need bearings pulled. I’m mechanically handy, but not an expert.

 

[AKPoser]

It will never be any easier than now while it is out. Plus, it seems like it would be a really great feeling to go back with essentially a totally fresh drive train.
Just my 2 cents.

My thoughts exactly!

 

[peesalot]

leak, grease, wise that thing is pretty dang clean. I'd take the pto off and have a look at tcase gears, you can see the bottom of tcase thru that window to check for evidence, should come out with oil but sometimes pieces will stay in there. Check thrust on idler in tcase at same time. That tcase should be fine spline on the output. Personally I like to find something to justify rebuild, X2 on you can do the tcase, the 4spd, IMO send to Georg . ( Cruiserbrothers/Valleyhybrids )

 

[POPO AGIE]

I rebuilt both of my 78 and yes, there are some special tools shown in the manual, but you can get by with clam shell bearing pullers to remove the bearings of the output shaft and the counter shaft.

For assembly you need a section of pipe, all thread a couple of nuts. You need to use the threads on the end of the output shaft to attach the tool too, so that you can pull the shaft through the bearing to seat and keep the thrust washer lined up with the slot and pin in the shaft. I just used the spacers and gears to stack everything up and turned the nut on the end of shaft to pull it through. I didn't have a welder so I had to improvise.

Get 3 lengths 12 mm all threads with the same pitch at the long bolts that hold the transfer case to the transmission adapter with nuts to pull the transfer case and transmission together because the weight distribution of each box makes it hard to get everything lined up. Mark the spacers so you get them in the right place on assembly because the photos in the manual you can tell what order they go.

Depending on the miles the rear output shaft and the input gear will most likely have worn at the splines from shifting gears and should be looked at. Mine had 103K miles and it was recommended that they both needed to be replaced.

With a Toyota manual it is not that bad.