Outer Limits 4x4 Board

shorty_f0rty wrote:I just need to figure out how to do it on the vehicle as there isn't a lot of room with the rear cross member where it is on a bj42.

A mate of mine, previous owner of my shorty, replaced his transfer with everything still on the vehicle. I remember him saying it was the biggest pain in the arse to do. Might pay to drop the box and transfer out together and swap them on the floor.

TWISTY wrote:

shorty_f0rty wrote:I just need to figure out how to do it on the vehicle as there isn't a lot of room with the rear cross member where it is on a bj42.

A mate of mine, previous owner of my shorty, replaced his transfer with everything still on the vehicle. I remember him saying it was the biggest pain in the arse to do. Might pay to drop the box and transfer out together and swap them on the floor.

Talking to Ray about it today and we figured dropping the gearbox cross member and angling the box down might give enough room.. I'll post up how I go..

I'd still prefer to do it on the floor if it was me. See how you go.

Well I've bought a landcruiser auto off ebay for $100, so it looks like I'll be doing this soon to my BJ70.

On a side note, just organised to buy a BJ74 for my brother (who spends 11 months of the year working in NW Western Australia) so for 90% of the time I'll have another cruiser in the stable.

shorty_forty, when are you planning on doing your transfer gears swap? I'd be interested to come watch/help if that'd be okay with you?

-Adam.

hotgemini wrote: shorty_forty, when are you planning on doing your transfer gears swap? I'd be interested to come watch/help if that'd be okay with you?

-Adam.

At the moment Saturday is all I have available to do the swap. I'm working to get the old case off before then.

ok.. its taken me over a week to get this done on my own at home with basic tools as I had time between a busy working week with lots of after hours work.

the bits you need.

from a transfer case attached to an auto transmission from a 60series.
- rear of the case
- input gear, idler shaft + gears and bearings and thrust washers.
- high/low range gears and shaft.
- front bearing retailer, rear bearing retainer and casing.

from a transfer case attached to a late model 6x/7x with manual 4wd shift
- front of transfer case
- rear of transfer case if you don't want the extra holes for sensors from an auto transfer.


from your existing transfer case
- front and rear output flanges
- hi/low shift lever (inner and outer)
- transfer case bolts front and rear.

some tips:
- undo the chassis crossmember for the gearbox and loose engine mounts to drop the box down
- dry fit all parts on a spare case if you have them (i had the donor box+transfer for the manual shift)
- you can get the rear off the case off if you drop are able to drop it down load
- check the hi/low shifter selectors as they are different!!
- use grease to hold the trust washers in the notches
- remember the detent plugs and where they go if you're using the rear hosing from the auto's transfer
- when removing the rear of the case try and remember not to talk the idler shaft with it. if it comes out so do the heavy idler gears.

- when putting it back together put stuff back in this order
0.5) front output bearing retainer
1) idler shaft in first, thrust washer, bearings then gears
2) input gear
3) rear housing
4) input spacer, pto gear, bearing and staked nut
5) other trust washer for the idler shaft
6) hi/low gears with hi/low selector
7) hi/low shifter
8) bolt up case, rear output bearing retainer, staked nuts done.

with this info you should be able to get the job done in a weekend easy.

This should be in the Bible, MODS!

Does anybody have a tooth count on these transfer gears
cheers
Gordon