Kzj95 transfer case assembly

[luciano122]

So I was pulling my rear cover off of my 90 series prado transfer case and managed to pull the output shaft out and now I am struggling to put the high low gear selector back on with the keys and spring things.
Does anyone know how or can give me some advice?
Any help would be good as I want to get it back on the road soon!

Thanks

 

[Shayne]

We need a batman style spotlight to shine in the sky calling BobMurphy to don his cape and come to the rescue

If he's not online Luciano a google search of bob murphy transfer case might provide the answer you need .

 

[BobMurphy]

Transfer Man here (Errrm that doesn't sound quite right ).

Yes, getting the Synchromesh assembly together and keeping it that way during assembly can be tricky. Expect to do this a couple of times

Its a few years since I last did one so pictures might be better than words.


1. The parts:-

2. Where the assembly fits:-

3. The three sliders run on these ramps:-

4. The three sliders are held in place by two overlapping spring circlips. Patience is a virtue !

5. The bronze cone then fits into the gear and over the sliders:-

6. The three sliders fit into the wide grooves in the input shaft (ignore the bronze synchro cone - that's where it ends-up after the sleeve gear is installed):-

That's about it, really. You have to be careful when assembling everything as it can all come apart if you let the gears slide along the shaft while installing the shaft.

Then go back to step 1. .

Note: Only Transfer Boxes for Manual Gearboxes have Synchro

If you get stuck come back and I'll see if I can help (these pictures are ten years old which means my memory is at least 50% smaller now).

Bob.

 

[Tractionman]

Good clear explanation and pics Bob, as good as (if not better) than any book.