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  #21  
Old 05-11-2010, 08:10 AM
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Originally Posted by RicardoJM View Post
Thanks, we are well into it now. It is a busy time with school activities but I am very optimistic that it will be back on the road soon.

Originally the transmission, t-case, bell housing and drive shafts came out of a truck in the junk yard - wow your twin brother Jacket is right; it is about time I got around to doing this project. The output shaft on the transmission had some severe wear so I bought Air Randy's old H42 and will be putting that one in instead of the junkyard special.
So, are the new 3.7 diffs out of a 60? If so, what are you doing about the difference in the bolt patterns on the driveshafts/diff flanges?
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  #22  
Old 05-11-2010, 08:35 AM
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So, are the new 3.7 diffs out of a 60? If so, what are you doing about the difference in the bolt patterns on the driveshafts/diff flanges?
I don't know what the 3.7 are originally out of, but it doesn't really matter. In 78 the spline count on the pinion shaft increased, and some prefer these later ones as more splines are stronger. I'm sure there is some validity to that, but there are plenty of older rigs with the "less strong" coarse spline pinion shafts in service and doing well after 40 years of use. Both will break, but I didn't find in my research that the later ones are a must have kind of deal.

The pinion flange bolt pattern off the 4.1 third members in my truck are from 1971 and do not work with the 4 speed drive shafts. I fussed with this more than I should have and with Corsair23 style have set myself up with options.
  • I picked up a pair of 3.7 third members that come with pinion flanges that match my 4 speed drive shafts.
  • I also picked up a pair of pinion flanges (coarse splined) from Ed Long (DEGNOL on MUD) with the correct pattern.

Interestingly enough, when going through my 4 speed tcase, the output pinion flange was not good. Rust had developed on the shaft and I could not smooth it out. If I had used it, in short order the seal would fail. Turns out the t-case output shaft is fine splined - so I picked up one of the universal pattern flanges to replace the bad one.
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  #23  
Old 05-11-2010, 08:46 AM
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Good info, thanks.
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  #24  
Old 05-11-2010, 05:17 PM
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Keep those engine removal/replacement pictures coming. Sometime in the next year or so I will be doing this, and I'm going to school on you!
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  #25  
Old 05-11-2010, 08:50 PM
L43dean L43dean is offline
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Default Fj 40 engine and 4 speed

Hello Ricardo! Are you going 4 on the floor (drill the hump,gasp!) or Mark Algazy's 4 on the tree design?
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  #26  
Old 05-12-2010, 06:56 AM
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Hello Ricardo! Are you going 4 on the floor (drill the hump,gasp!) or Mark Algazy's 4 on the tree design?
Dean, good to see you back on the interweb thing. One of the previous owner(s) of my switched over to 3 speed on the floor from 3 on the tree before I bought the truck; my hump has already been drilled and violated.
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  #27  
Old 05-12-2010, 06:59 AM
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... my hump has already been drilled and violated.
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  #28  
Old 05-12-2010, 08:45 AM
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... to swap over the hi-low shift arm from my 3 speed case to the 4 speed case.
Why not use the 3-speed case for the lower gears? Or put the 3-speed gears into the 4-speed case (slightly stronger case) with idler shimming? FWIW, rebuilding a t-case is pretty easy. The only issue I had was getting the rear output shaft unmated from the inner bearing race, but a friend showed me a trick that worked well.
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  #29  
Old 05-12-2010, 11:27 AM
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...my hump has already been drilled and violated.
I wish I had more space to add that to my sig line
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  #30  
Old 05-13-2010, 07:17 AM
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Why not use the 3-speed case for the lower gears?
While I'd like to layout a well reasoned, rational that will bring clarity to new people that read this thread and provides justification for others who have made the same decision - fact is I just and can not say.

This project is a long journey with many forks in the path. Those that have taken on large projects like this have had to deal with the same sort of "this would be easier while I'm in there" types of decisions. I can say that one of the aspects I enjoyed was researching and debating each of these forks in the path. I learned quite a bunch talking to others and reading all the information available on the web.
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