ok this is gonna sound weird so bear with me

my brother has an fj-62, and the input gear in the transfercase was worn the output shaft splines very thin. so much so that he's getting weird noises and vibrations. He figured with 200,000 miles it was time to get a new truck so he got a late model 4runner, but he still has the cruiser. I recently heard of a way to weld the PTO gear to the input gear, and essentially fix the unit for a while longer, rather than tearing apart the auto and putting in a new output shaft.

Anyone have pics of this process, or know where on the web I can learn more about it?

I dont have any PICs but I have done it and posted about it before. Basically, you have a drive gear, spacer and PTO gear. The drive gear rides on slightly different splines than the pto which comes after it. On US model 60 series the PTO is not used so the machined portion of the shaft does not wear under it. I weld the whole mess into one part. There is very little torsional (SP?) stress on it as the PTO gear, in effect, will take the majority of the load. The spacer is the weak link as it is not splined and could eventually shear off of the other gears. I have not seen this happen but it is possible. A way around this is to get another PTO gear and cut the outer teeth off of it so all that is left is an inner splined hub. That, with a bit of work on the spacer, will weld up to the PTO gear.It makes no difference where the spacer goes in relation to the shaft. All that matters is that there is enough combo of spacer and gears to provide a place for the TC output bearing to seat against.

McNamera in OZ makes this pre cast. It does the same thing but I understand that it allows for the different machining on the inner splines where the drive gear rides. It runs around $380 + shipping + contacting them+ getting them to sell it to you blah, blah... PITA to work with.

More I think about 62 may not have a spacer but has a longer splined portion that rests against the drive gear...Been building 60 cases as of late so it is all a bit hazy right now but I hope ya got the basic theory.

Doesn't sound weird at all to me. Very common, actually. Lemme guess, the tranny output shaft looks something like this:

http://www.yankeetoys.org/KLF/Clifford/TCaseRR/Splines2.jpg

I solved it by installing a McNamara gear in my t-case, that was 2 years ago. No more clunk. Here's where to get one: http://www.mcnamaradiffs.com.au/driveshaft1.html

David, yes you are initially correct that there is a spacer on the tranny output shaft. Here's a pic of the old gears/spacer on the right, the McNamara gear is on the left:

http://www.yankeetoys.org/KLF/Clifford/TCaseRR/NewGear1.jpg

A bunch of us are installing several of these gears this weekend. McNamara is apparently getting better about responding to email, latest price seems to be about $300 including shipping.

Replaced mine with a McNamara. Clunk went adios.

TJK

WIsh I could come up to that bash! Just too much going on. If it makes you feel any better I have 2 cases to do this weekend!

Yeah, I can't make it either. They have lobsters.... :smokin:

TJK

:barf: they frying the lobsters in 90 wt? that'd be cool! :barf:

Believe they chose ATF. Some of them on low cholesterol diets....

TJK

WIsh I could come up to that bash! Just too much going on. If it makes you feel any better I have 2 cases to do this weekend!

We wish you guys could too! 5 t-cases to rebuild in none weekend!! :eek:

those cases out of the trucks? or you all planning on pulling them getting them rebuilt and installing? Wow that will be a production. I'm guessing 2 guys on press duty alone! I hope they all bring their junk cleaned and ready.. It would suck to spend 3 hours in the parts washer getting ready. Not all that challenging sounds like a great weekend of fun!