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Discussion Starter · #1 ·
I have a 78 FJ40... on my way home from a day of wheeling last
weekend, I heard a really nasty grinding sound coming from my
transfer case. It has been there for a while but hasn't gotten any
worse... I figured I would drive it till the case went and I needed
to rebuild it. Well, it's not a grinding at all, the tcase linkage
is rattling... really bad at high speed/RPM. I still get good
contact with the case and everything shifts fine... but is there a
way to adjust the linkage to tighten it up? And could this be
indicative of a larger problem... such as a bad motor mount of trans
mount?
 

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Try lubricating and tightening up the pivot points. If that doesn't work, check to see if they are worn out and need replacing.
 

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Is it actually the linkage, or could it be the shifter rattling? I've quieted the shifter rattle by slipping a length of appropriate-diameter heater hose over the shifter shaft, and then put on a velcro camo cover from Specter. :)
 

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Discussion Starter · #4 ·
It probably is the pivot points... the rattle comes in through the shifter but even when I hold it, I still hear the rattle. Would I have to drop the trans and tcase to replace the pivot points or can it be done while they're still in... it seems kind tight.
 

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Desert Rat
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If you can get a wrench onto the hex at the base of the main pivot that screws into the side of the tranny, you can unscrew the shaft out of the tranny and drop the lever assembly out that way. Shouldn't need to pull the trans cover. Definitely don't need to drop the trans. Hth
 

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Discussion Starter · #6 ·
Well, wheeled the 40 a few weekends ago and the tcase is pretty much shot. I tightened up the pivot points and eleminated the rattle in the linkage... but still heard lots of noise. Got home and changed the gear oil and found lots of metal shavings. I guess I'm looking at a rebuild... I won't be wheelin' for a while. :(
 

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Pull the front output shift fork first and see if it is worn out. They tend to wear out if the oil level drops below the output shaft.
 
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