kzj 78 PTO drive

[uptomynutsinruts]

Hi all,

This may be a dumb arse question but do the 78 Prado's come with a drive gear in the transfer case? I've bought a 70 series PTO winch and was wondering if there is one in there or if I'll have to retrofit something.

Cheers

[Big]

best way to check is take the cover off.. it could be there but highly unlikely.. but can get them in trademe.. and is not that hard to install

[uptomynutsinruts]

Cool ta, so I take it none of them came from the factory with the drive in there? How long does it take to throw one in? I assume its a transfer case off the gearbox and onto the workbench sort of a job?

[Big]

on truck job.. it'll be a split case so just undo bolts pull apart..get the right drive gear and spacer then just throw it in.. not hard but timely job..

[imsohi]

to my knowledge no prados came with the gear from factory, you wont need to remove the complete transfer just the rear part of the case. Try and get the spacer aswel as it will save having to cut your one down and save time and the only other thing you will need out of the box is a 36mm socket prob a coupple of hour job completed under the truck.

[imsohi]

on truck job.. it'll be a split case so just undo bolts pull apart..get the right drive gear and spacer then just throw it in.. not hard but timely job..

bugger bet me to it

[Big]

on truck job.. it'll be a split case so just undo bolts pull apart..get the right drive gear and spacer then just throw it in.. not hard but timely job..

bugger bet me to it

[uptomynutsinruts]

Bloody hell, never had people fight over telling me something!! Haha cheers for that guys

[derk]

other than throwing the drive gear in you have to get the long spacer turned down unless you happen to get the correct length short spacer with the drive gear

[uptomynutsinruts]

Awesome Derk cheers, I take it the spacer goes between the gear and the case on the shaft to stop the shaft/gear moving sideways?

[derk]

yep if theres no drive gear theres just a long sleeve spacer that sits on the shaft or if you've got a drive gear theres a short sleeve spacer and the drive gear sitting on the shaft if you pop the pto plate off the side of the transfercase and have a look inside you can check to see if theres a drive gear in there (which there wont be) and you'll be able to see the long spacer sitting on the shaft

[kbushnz]

Have a read thru my thread on my mid mount PTO. The first part shows what if looks like with a gear thru the hole and an overview of the process to split the case and swap in gear.
viewtopic.php?f=18&t=25791

[uptomynutsinruts]

Hey kbush was hoping you'd pop up, how long did it take you to fit the gear? And I assume its just drain xfer case, remove rear half of case, remove snap ring/circlip, remove bearing (do you need a puller?), cut spacer down by x amount and then reassemble?
Thanks for all the help guys

[derk]

while its all apart you want to check the idler pin for any pitting and replace it if its suspect looking and check the thrust washers for wear and measure the end float its not expensive to replace the pin and washers while its apart

[Big]

ALSO is a must is make sure you put in GL4 gear oil.. all newer oils will fk ya case, thrust washers and then your in for a new xfer.. Just letting you know Kbush is spot on

[uptomynutsinruts]

Funnily enough I was having the GL4 GL5 debate in my head today, couldn't remember which to use so thanks for that, and cheers Derk for that info

[kbushnz]

Hey kbush was hoping you'd pop up, how long did it take you to fit the gear? And I assume its just drain xfer case, remove rear half of case, remove snap ring/circlip, remove bearing (do you need a puller?), cut spacer down by x amount and then reassemble?
Thanks for all the help guys

I don't recall exactly how long it took as I did it in squirts and farts... I would say as long as you have the gear puller and everything goes to plan... A good day would work. In a factory prado the exhaust runs past the transfercase. And you may have issues with getting past it.
I didn't have this issue as my exhaust was cut down the last time I dropped the whole case for repair.
You also may need to drop the rear of the case down a bit so the case doesn't catch on any of the floor frames and you can get to the bolts.
Also there is a ball and spring for the detents to Hi / Low.... dont lose them....You can put them back in after its reassembled.

I tried to reassemble using a new gasket between the cases.... Didnt go to well.....trying to hold it in place and offer up the case. I gave up and used locktite master gasket goo.... Just had to be sure you have enough gap between the idler gears on the solid shaft.

You can download a manual for the LJ70 which has the transfercase strip down proceedures.

[mudmike]

to be honest the drive gear was the easy and fast bit as it is straight forward and the manual shows it all and parts are off the shelf. hooking up the control lever and the custom mounts for the drive shafts took more time to get right. I used a 60 series 3 piece drive shaft for a front mount winch. if I did it again think the 2 piece would be alot easier.
Also for the controls would look at doing a morse cable like a nissan runs rather than cutting hole for the lever.
good luck is well worth it as they are great mod.
Mike