Troop Carrier

Submitted: Saturday, Jan 08, 2005 at 13:36
ThreadID: 19178 Views:5055 Replies:8 FollowUps:3
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Does anyone know if there is a part that is a pipe that fits between the gearbox on a troopy and the transfer case? If so is it worth whle fitting and where do get them?
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Reply By: Member - Geoff M (NSW) - Saturday, Jan 08, 2005 at 14:27

Saturday, Jan 08, 2005 at 14:27
Wouldn't happen to be having trouble with transfer case oil level falling and gearbox oil level rising would we?
Best fix is change the bi-directional neoprene seal between the two.
Second best fix is to manually transfer the excess gearbox oil back to the transfer case.
I thought about the pipe idea, then realised the gearbox and transfer case filler plugs are at different levels.

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Reply By: Bob Y. - Qld - Saturday, Jan 08, 2005 at 15:01

Saturday, Jan 08, 2005 at 15:01
If you go to hydraulic hose specialist, like ENZED, they will/should have a kit ready to go, for this problem. Well, they sell 'em in Mt Isa. Price around 40-50 bucks.

Bit fiddly when you are doing tranny service, having to remove both plugs and hose, but they do work well. As long as oil levels are correct initially, they will stay the same.

If you have big K's on the troopy, then it maybe an idea to do as suggested above, as the output shaft/gear, in transfer case, may need checking. At best, the BIG nut on rear of output shaft would need tightening. If this nut is not at correct torque, then the spline wears on output shaft/gear, and in extreme case, you lose all motion, either forward or reverse. Now it's getting expensive....


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Follow Up By: Member - JEFF - Saturday, Jan 08, 2005 at 15:52

Saturday, Jan 08, 2005 at 15:52
Bob Y

Didn't know there was a problem in this area before!!

IS it a common one or no? I have a 1999 model with a 1hz diesel only done 86000 Klicks. Or is it mainly a older ( Kilometre wise) problem??

Thanks,Jeff .....Sydney
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Follow Up By: Bob Y. - Qld - Saturday, Jan 08, 2005 at 22:29

Saturday, Jan 08, 2005 at 22:29

Have only seen it in 2 vehicles, one on the station, and an opal miner's vehicle that becoming stationery, after crossing a creek, while the rain tumbled down in...November.

Both these were 75 series vehicles, one a 2H, and other an early or mid-90's 1HZ. Feel it may be a product of high K's, hard work, or perhaps that model. A vehicle caught in boggy conditions, needing much rocking and purging, forwards and back, would accelerate the problem. Also as mentioned the nut can work loose, with wear, and needs to be re-tensioned to keep the 2 gears locked together on the spline.

Of the 2 gears in the t/case, only one wears the spline(correct me if I'm wrong), and a bush fix is to weld the 2 gears together. A bloke used to advertise a special one piece gear for this application, but haven't seen anything in mags for a year or 2.

Jeff, I'd be surprised if a well maintained vehicle, doing mostly bitumen/touring work, would suffer this fate. But as mentioned by Peter below, the wear can be extreme, and there may be a zillion tojos running around, just waiting for someone to give them the BIG SQUIRT, and strip the top off the remaining spline.

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FollowupID: 350808

Reply By: glenno(bris) - Saturday, Jan 08, 2005 at 16:37

Saturday, Jan 08, 2005 at 16:37
If the gearbox and tranfer case levels are ok dont do it . Spend the money on some new oil .
AnswerID: 91951

Reply By: Peter 2 - Saturday, Jan 08, 2005 at 20:25

Saturday, Jan 08, 2005 at 20:25
I've had to replace the main shaft on my 1HZ troopy at 120k not long after it started pumping oil from the transfer to the gearbox. This was on a privately owned vehicle mainly used for long outback trips, no commuting whatsoever.
Common problem, what happens is that the main input gear on the mainshaft flogs the splines out on the mainshaft and the inside of the gear, by the time I pulled it all apart there was only a 1mm high triangle instead of a 4 mm square spline. New parts from Toyota (gearbox main shaft, bearings, seals and gaskets, transfer input gear, bearings , gaskets and seals) was approaching $2k for parts alone! I used Don Kyatt shaft, gear and bearings and Toyota seal and gasket kit as the DK ones leak.
A simple test to see if you have a problem is to remove both the PTO cover and the black tin cover on the back of the transfer (after draining the oil). Hold the main input gear with one hand (gear closest to gearbox) and then see if you can rotate the shaft with either you other hand or a socket on the nut.
If there is any movement between the two you have a problem.
I used to run a hose between the filler plugs on earlier troopies but if the post 1990 ones start pumping oil you are in for problems as a rule.
AnswerID: 91962

Reply By: destavesta - Sunday, Jan 09, 2005 at 09:14

Sunday, Jan 09, 2005 at 09:14
Thankyou al for the quick reply, I was told that this was a preventive measure as you have al said I will leave it alone. It is fine at the moment the troopy is a petrol and nly done 78 ks not bad for a an 86 model. Once again thanks. I don't suppose anyone has a forward facing toyota rear bench seat to suit at a reasonable price?
AnswerID: 92014

Follow Up By: Member - Davoe (WA) - Sunday, Jan 09, 2005 at 12:57

Sunday, Jan 09, 2005 at 12:57
I have that kit in my camper it doesnt really work as my transfer case gets too full of oil and starts leaking from a few seals. Best way is to check your levels when servicing (5k) and drain excess oil fom one and refill the other if there is a problem
FollowupID: 350849

Reply By: Troopy Travellers (NSW) - Sunday, Jan 09, 2005 at 09:26

Sunday, Jan 09, 2005 at 09:26
My motor mechanic installed this flexible hydraulic pipe connection on my '89, FJ75, 280,000km, troopy, last year. It wasn't all that expensive, I had it done at the same time that I was having the front wheel bearing seals done, so the price was somewhat hidden in the total cost. The motor mechanic recommended it & it seemed like a good idea to me.
AnswerID: 92015

Reply By: Member - Roachie (SA) - Sunday, Jan 09, 2005 at 13:16

Sunday, Jan 09, 2005 at 13:16
John Rooth (Aust 4WD Monthly magazine) showed how this was done on his old 45 series in an article several months ago (could be 12 months maybe).
Apparently it is a common issue with the Tojo "workhorse" versions, but can't seem to see any reference to it being needed in the 60/80/100 series.
Good luck.......
AnswerID: 92036

Reply By: Member - Phil G (SA) - Sunday, Jan 09, 2005 at 20:13

Sunday, Jan 09, 2005 at 20:13
The better fix for the early 40, 55 and 60series was to replace the single lip seal between gearbox and transfer with a double lip seal that was used for the 60series with automatic transmission. Most owners put up with it, or fitted the tubing kit thats at many 4wd shops. My 55 series used to pump from the gearbox to the transfer, and my 60series pumped uphill in the other direction.

Not sure how common it was on a 75series - maybe Toyota finally fixed it??
AnswerID: 92087

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