Where did all this metal come from? (1 Viewer)

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Tore down a transmission and transfer case assembly that was leaking externally(and probably internally as well) between the two gear boxes to inspect, reseal and gasket.
JTC01.jpg
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Parking brake seal surface is not horrible, however that groove on the aft section of that housing is not good.

:eek:
JTC03.jpg
JTC04.jpg
 

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Input gear...
JTC05.jpg
JTC06.jpg
 

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More metal...
JTC07.jpg
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JTC09.jpg
 

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High speed gears...
JTC10.jpg
JTC11.jpg
 

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More...
JTC12.jpg
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Range fork....
JTC13.jpg
JTC14.jpg
 

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Junk transmission output shaft...
JTC15.jpg
JTC16.jpg
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Trollhole

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Toast.

Looks like the case had water in it at one point and rusted. Then the rusted stuff was drain with a few oil changes. All the gears look pitted causing the gears to eat each other causing the metal.

My best guess. That or the idler shaft bearings and shaft are shot. Which they would be anyway with all that metal.
 

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I guess there could have been rust on the gears but the low speed gears do not look anything like the high speed gears.

It looks like damage indicative of a case ran low on oil for a while...



:meh:
 

inkpot

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Yup, that would be my first guess. Ran without much/any gear oil for a while, and /or ran with water mixed into it. I have seen a lot of output shafts like that, some with the splines deformed so far that the gears would barely come off after breaking the first puller I used. Condolences. John
 

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what caused the groove on the parking brake housing?

That would be an indicator of transfer case main shaft bearings that are completely out of adjustment/shot and continued to be operated. Picture the parking brake drum running in an exaggerated circle, rubbing on the parking brake backing plate.


This is far from a shocking discovery considering the many other issues that have been uncovered on this customer vehicle. Front output flange nut reused and not staked, rear output nut reused and not staked, body not even secured to the frame, partial de-smog but nothing really capped off or sealed. It was purchased from a company that focuses on Vintage vehicles primarily for the Off Road enthusiast.
 
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what caused the groove on the parking brake housing?
The one I had like that was caused by the parking brake lever coming lose from the shoe and dragging on the drum spindle.

VINTAGE? Kind of sounds like a Mushroom job.
 

kiwidog

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TC

So Poser,

What was the cause?
Looks to me like lack of lube or not the right lube, or maybe it had Lucas oil in it?
The output shaft is re-useable IMHO however a good weld job and re cut the splines with a small disc grinder and a couple of files, works. Have one I just pulled apart with the output shaft splines more than half worn through and the gear splines even worse, wear begets wear. The blackness on the parts says heat to me and lack of lube.
So do you rebuild it or find a replacement?

Thanks jb
 
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At least the customer probably got it on the cheap;)

Maybe there should be a sticky for all the potential off road enthusiasts - probably wouldn't help. Educations are usually expensive or time consuming. Often both with Land Cruisers.
 

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