The Toyota Landcruiser Owners Club

[MikeyB]

Good tip thanks Roger. I might order some diff plugs and put them in the gearboxes.
Day 6 was a biggie.
I got the gear case on, although i thought while trying i wouldnt be able to achieve this, it was grim for a while. I had mismatched the holes, with the dowel pins there it is a little bit unclear, well it was for me. I was actually trying to get it higher to match some other holes than it should be. Once i realised this and dropped it a bit it went in ok. Which surprised me giving how rough i had being. I dont think it hung at all (ie weight was not put on the input shaft ), as i was actually trying to lift it higher . It buttoned up ok and so did the starter and clutch slave cylinder. If there were two people. One for each side of the housing plus a jack that would be a much better set up.

The transfercase installation was no fun. Its a very unfavourable shape so i had it balancing on one leg of the jack and did my best to get it in there without hanging. Its very heavy. Again if you had two people and a jack itd be way easier. Also cleaning up the dowel pins beforehand would lead to a more smooth operated fit to minimise hanging chances.

Im buttoning it all up so it will be ready for a test drive in the morning, such a big occasion after almost a week of it i might consider wearing a suit.
Will update how she goes.

[Google]

[MikeyB]

Day 7
Test drive went well. It was a bit noisy for a split second as i went into each gear for the first time, my fault for not pre-oiling. But after that she was very good, quieter than previously. This may be due to a bearing on one of the shafts not being tight up against a spacer when i took it apart, allowing the spacer to rattle a bit.
I dont want to load her up yet as im still a bit apprehensive but she seems good. It took me about 6 weeks after i fixed my front diff to not be sitting there with listening ears for any strange sound.
I did have trouble with the transfercase shift lever. It doesnt want to move. It looks like its in HL position but its actually in HH as the centre diff isnt locked. Im not concerned much as i still drive it fine since the centre diff isnt locked and i didnt have the case apart so i didnt do anything with the gears in there. Im picking ive installed it wrong somehow. theres some funny metal spring looking thing and you can see a slot at the bottom that the shifter goes into, maybe ive got that shifter a wrong way in somehow but if anyone has a tip on that itd be appreciated but i wont do that til tomorrow.
Im off on another drive!

[MikeyB]

Ive reread that manual and it doesnt state a thing about it, just says what ive done.
But a post online says something about lining up some forks in there but that was for a 4runner, so il wait til someone says something as the car is running so well theres no rush for low range until the wet season here- May/June

[BobMurphy]

Mike,

My latest e-mail has the Transfer Lever installation procedure - with a picture.

Good to hear its back on the road - well done !

Bob.

[MikeyB]

Thanks a lot again Bob, you should put out your own workshop manual.
And yes having the prop shaft my way does make sense due to the bash plate engine guard providing cover
Its great to be back living in the era of the automobile.
Il try that recommendation in a few days and report back here how it went.
All in all, with one afternoon and nights rest its a job if i could go back a week id do it again myself. The manual says that dismantling and rebuilding the gearbox is the hardest part and should only be done by a specialist, i disagree, for me the hardest part is lifting the boxes in and out. So if you can get a garage to do this for you and you can pick the gear train up on a trailer and take it home to work on it this would be the luxury option but otherwise it can be done by yourself but find something to bite down on between your teeth.

[diggerdave]

Nice write-up and much respect for doing a pig of a job on your driveway...
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1997 KZJ90 3.0d, 2" suspension lift, 235/85/16 Cooper STT Pros. 217k hard miles

[MikeyB]

Thanks Dave, i did it on the lawn which was a better i thought than the stony driveway, so im glad it wasnt winter
The advice from Bob about how the transfer lever install was correct. The manual does not have this at all so here it is reproduced without Bobs permission

Remove the lever from the turret and use a long screwdriver to click the right-hand selector shaft back into the 'Diff
Locked' position (HL). This aligns the two selector blocks as per my picture (you don't have to remove the turret to do
this).

Now make sure that the pointy end of the Transfer Lever goes into the gap between the blocks - keeping the spring to
its left.

Re-fit the retainer and the lever should be sprung to the right, move it to the left and click it back into 'H' and all
should be well - with the diff 'open'.

The right selector seems to move forward so i levered it back, and you do have to keep the spring on the left which makes you have to force things a bit but its entirely accurate as shes driving now in Low range or High range whenever i select it.

Job Done.
Thanks for no one talking me out of it and big thanks to Bob-invaluable

[diggerdave]

[BobMurphy]

[diggerdave]

You're a proper redneck Bob!  


When I was contemplating removing the TB on mine, I wondered about lashing up some sort of makeshift jig out of bits of an old pallet to hold it at the correct angle, with skids or even castors on the bottom to slide it in or out of position. But knees and chest are much better.
_________________
1997 KZJ90 3.0d, 2" suspension lift, 235/85/16 Cooper STT Pros. 217k hard miles