Offroad-Express

I have a hj61 here and I am after some advice/instruction on removing the transfer case from the gearbox first of all is this achievable without dropping the gearbox? And second I have removed both drive shafts and the pto unit from the t case and all bolts but is there another one inside the t case that needs releasing before it will move?
Any help would b greatly appreciated
cheers Nick

split the box and remove the idler shaft and sprockets

there is two bolts behind them

keep track of bearing and disk placements as you pull the shaft out it will help in reassembly

Ok thanks, I have the box all ready to come appart but the lock nut on both the front driveshaft flange and the transmission output shaft I can't crack,
is it safe to put heat on them?

ol_smokey. wrote:Ok thanks, I have the box all ready to come appart but the lock nut on both the front driveshaft flange and the transmission output shaft I can't crack,
is it safe to put heat on them?

The nuts are staked.. so either use a nail or screw driver.. to open it up a bit then it should just unscrew.. then just pull everything apart as you see it..there are from memory 4-5 bolts inside that you need to undo.. also get a big container as when you take it off the idler will come out too and all the gearbox oil will drain out .. been there done that
it's a peice of cake really...

Yea have freed up the tops with the chisel but not budging,???
The first one, the rear drive flange nut was sweet as?

Just heat gun it hot but you'll end up replacing the seal.. otherwise should be sweet.. or just cut the nut off and replace the nut..

So does anybody happen to have a whole h55f box that I could swap in for this 1? if so how much? the 1 36mm nut is the only thing left and I'm not game to cut it in under the truck so the box will haft come out and itl b quicker to swap 1 in and il rebuild mine properly later....

you could use a nut splitter.. saves grinding..?

I couldn't get one of those nuts undone no matter how I tried, even with a long bar, a rattle gun was borrowed that will 'undo anything' and that didn't work so I called firestone and the dude with 3/4 drive rattle gun came for mobile truck tyre repair and got it off, didn't even break a sweat, 'rattled' for about 2 secs then off.

is it behind a diesel or petrol engine as the input stafts are differant

maybe have more weetbix...

It's appart... Any 1 kno of a transfure case or allot of the parts for 1 for sale?

ok Nick what's going on....
yes you now have the t/box off....
and now after the internals?????

what did you do and how????

and what are you after?????

yes the bearings get a bit sh--ty and seals go but that's bits off the shelf from Don Kyattts

but gears/ sprockets and other stuff????

come there fella let the story out

you will feel better afterwards....I promise....

Haha ok then well iv had this cruiser now for maby 3 weeks and on wensday I was driving down the road and it was getting really whiney on deceleration so I stopped had a look under the truck and the idler shaft on the transfer case is sucking out about half an inch the locking nut has sheard off, so I turned Arround an carefully went home by then it was maby another half inch out....

Since then.. I lernt how to remove a transfer case on a dirty old L/C but, it's appart except for that 36mm nut still on the upper most shaft in the t case and the needle roller bearings from the idler shaft are lunched and have gone every where and lots of heavy scratching on the shaft and inside of the gear that came off it, mecanic mate said they are throw away but Ross was gna look at the parts 2day, pluss the inside of the housings where the idler shaft was moving free are pretty ugly 2..

Haha so your pretty up 2 date now any advice or ideas are greatly appreciated

strong bar on the output shaft with a tube over that, apply pressure and hit with a big hammer, that should sort out the 36mm nut

now im a thinking that a drive up to papakura might be in order, bring up your old t/box and all the bits and let me have a looksee,

measure the idler shaft o/d and let me know. it will either be 32mm or 38mm

im sure i have a range of bits for booth, but it would be good to check before your little journey

It's a 38mm
Ross said new shaft and gear but il get the rest off and bring it to you if you think you have parts that can help, il have a go at that nut again now

Some of the guys in aussie use the starter motor to turn against a jammed strongarm to remove these.

I used an angle grinder n cold chisel