Notes: Rebuilding a 1987 Toyota Land Cruiser Split Transfer Case

Ron Connelly, August 2001


See the pics taken on disassembly of the Tcase

See some pics of parts of the reassembly of the Tcase

Pictures Comments

The bolt hole circled in green will need to be tapped & plugged if you are installing a Toyota H55 5 speed transmission. I tapped the housing from the other (transmission) side for a 1/4" NPT plug. I plugged from the other side so that this housing could easily be used with a 4 speed transmission again in future.

This picture was provided by Chase Gregory. Thanks, Chaser, for all your help!

Pics 2, 3, & 4 are where I was trying to figure out if I should use the Oring in the ebuild kit behind the input gear. I finally did not, and all seems to be fine. The factory manual said to use it, but none came out when I disassembled the case.

This is the input gear installed with no Oring between it and the bearing on the tranny output shaft. As you can see, the gap is about an 1/8"

This is the input gear installed with an Oring between it and the bearing on the tranny output shaft. The Oring used is the one in the next pic below. The gap here is almost 1/4" or so-- pretty big,

I reassembled without the Oring..

The only Oring in the rebuild kit that looks right is this one. It has a .137" cross section.

There was no Oring that came out of the tcase here, but the factory manual says to install one...

I did not use one, and the gears all had the proper engagement without it.

This shim was behind the race in the rear output cap. There was no shim in the front of the output shaft assy.

I reassmebled the case withthis same shim in the rear, and had what felt like very good preload on the assembly when I put it back togather.

At this writing, the rebuilt tcase has a couple thousand miles on it and is trouble free. That includes about 100 miles offroad in Baja.

This is an oil slinger to help ol the front output shaft. Don't mistake it for a shim.

Here are some items I have not yet figured out where they go:

The 2 large Orings are for each end of the idler shaft.

The aluminum washer in the upper right is for the drain plug-- there's another identical one for the fill plug.

The medium Oring is probably for the OD of the speedo gear adapter-- I am not sure what the small Oring for. It is probably for the ID of the speedo gear adapter, but the seal in mine is not an Oring, but different. I didn't replace it (and it now leaks)...

See the pics taken on disassembly of the Tcase

See some pics of parts of the reassembly of the Tcase

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