OK, A While ago I asked a question about my leaking and whining four speed transfercase on a BJ40 and a rebuild was suggested to me. Well this is the first time that I attempt to do this, and I have to admit i have some questions and doubts:A) Do I need to remove the unit in order to put new bearings and oil seals on the output shaft ? B) Is the wear on the bearings on the output shaft the most likely reason for whining. C) If I have to remove the gearbox/transfercase do I have to remove the fuel tank as the haynes manual suggests ? Can I not generate enough space by removal of the handbrake drum and extension housing ?

Any tips are more then welcome, or a reference to a site who deals with the removal is appreciated. Thanks,

Walter :question: :question:

what year BJ40? Might make a difference as in '79(in US FJ40's) the gas tank was relocated and might make things harder. Have not done it myself on a '79 and newer, but for the one piece cases the case needs to be removed... You can do the split cases while on the truck b/c the back half comes right off and allows easy removal of the output shaft and gears...

-Brett

I have the same problem. Mine whines because the previous owner ran it without oil for a bit. Just long enough for it to start whining.

Gears whine while bad bearings make a whirring or rumbling noise. Gear whine is often related to bad bearings as they allow the gear to tilt on the shaft. The weak link in cruiser transfer cases is the idler gear center shaft and bearings. You can remove the T'case without removing the tranny for both the J30 and split cast types. I just find it easier to drop the whole assembly with a hoist from above the tranny. You don't have to remove the gas tank if you want to remove the tranny hump (cover) and drop it from above; you only have to prop it up to get at the hump bolts underneath.

in Oz, from 1980 onwards we got the split case in our BJs im not sure about you...but our tanks were also under teh floor in these models, and its doable, not fun, but doable