you could do a double seal on the rear of the tcase. mudrak has been selling those with some success. keeps the gear oil out of your parking brake drum.
but really what you wanna look at is the rear of the motor. getting the tcase down is a 2 banana job, getting the 420 down, once its in there is no fun (damn those things are heavy). i'd look at your motor rear main seal, etc.
are you going to be putting in a new rear cross brace for the tranny/tcase?
i would definetly replace all the accesible
t-case seals while you're at it. input, front output and rear output( with the 2 seal setup if you can).
the t-case saver is a good idea too, especially if the case is out anyways. makes the saver install a cinch.
one more thing i would change is the pilot bushing. it's cheap insurance and only takes a few minutes. use a bronze/oillite bushing. easiest way to check is to use a magnet. if the new bushing is magnetic, find another one that's not. the magnetic ones are too hard, since they have some ferrous metal in them and can and will cause premature wear on the trans. input gear where the pilot bushing rides.
also make sure to soak the pilot bushing in oil really well (overnight) before installing it to prevent it from drying out.
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if you have a welder you could use that crossmember to make a t-case saver. I wish I had a digi cam to show pics of mine, cuzz its hard to explain. but I basicly put the crossmember on upside down (or however I needed to so the arm ran along the top inspection plate) than took some 1/4 inch steel put it on top of the inspecion plate, than wleded the 2 together (and of course chopped off the other arm)
seems real beefy to me, my AA input shaft broke before my T-case but I'm really really hoping it was a deffective shaft.
if you're putting in a 420, you'll need to change out the pilot bearing anyway to fit the 420 input, so thats a given. the rear cross is to help for the added weight of the 420. some folks say you don't need them, but the 420 is a much heavier tranny the toyota stock. putting in a brace at the back of the tcase is a common way of helping brace the entire tranny/tcase. lots of folks offer prefabbed ones (advance adaptor comes to mind and i think john pardi is making one too). but if you're looking to save $$, you should be able to fab one up. there was mention of tcase savers further up in this thread. there are 2 designs that i know of, one that goes along the top, and the other that fits on the rear. many folks swear by both. after having seen a late model split case broken in half from bruce millers 60 this summer, i think anything you can do to strenghten the case is probably a good thing.
you can see both at this link http://www.pirate4x4.com/cgi-bin/ubb/ultimatebb.cgi?ubb=get_topic&f=5&t=003995
don anway (reddog on this board) makes the top one, and john pardi makes the rear one.
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