Topic: Project BoostedRunner, SOLD

[TURBO]

oh hey, can you take a pic of the back of your trans??? if that was worn or messed up some how that would alow the counter gear to walk forward

[zembalayan]

Very good comments and questions -Matt- and Turbo!

[pumkin toy [OP]]

Man i thought i was the only one who had problems with gears.  We iust arnt breaking the same ones though..

I totally stand behind marlin on tcase components after he gave us his rear case after my buddy broke some stock gear in his 4.7 cases at mcr last year.

With that said maybe try a differrnt brand as they make work for you

i agree and completely believe that marlin sells the best quality toyota parts out there.  I'm not trying to make this into a marlin bashing thread at all, i am just trying to get feedback from people who might know more about the situation

Any chance you have a pic of the obstacle you were on when it happened?

I wish i would have taken a pic right after it broke just so everyone ould see how much of an un-stressfull obstical it was! haha

its crazy that you keep braking them tho

yeah they really shouldnt break that easily.  i could understand if i was bound up and hanging fame hardcore and all wedged in something, but that was not he case at all.  i was climbing up an obstacle that i probly could have done with my 99 silverado on 33" tires!

If they do warranty, i would try and spend the extra cash on getting there comp ones. If not maybe send them off and get the cyro done. this is crazy, theres no reason you should have broken two sets. maybe its time to go to stock 2.28 or even try another brand of 4.7

yeah i really do want to upgrade to chro-mo for sure!

[pumkin toy [OP]]

i tried looking for info on your rig, but this massive 77 page thread is kinda ridiculous LOL, (in a good way)

who built the rear case? how old is the bearing next to the broken teeth on the counter shaft? is it a new or used bearing?
is/are/were the #1 and #2 housings paired from the factory? what condition is the main bearing in? for that matter, how do all the bearings look? did you replace them all after the first set of gears went bad?

also, what engine you running? hp? trans? tire size?

when i first saw these pics, i thought it was a bit odd...

also, what number gear set are these?

the rear case was built by a friend who owns a toyota specialized off-road shop in Colorado, I have complete confidence in his abilities.
I couldnt tell you how old te bearings may or may not be, but i did check everything over for excessive wear or heat issues or slopiness and everything looks fine.  these sets of gears i broke were in two different cases.  I didnt break one set and then put new gears back into that same case, so there should be no issues with broken metal in the bearings or something like that
i couldnt tell you what # the gearset is, i dont know where to find that out

[pumkin toy [OP]]

is this the t-case the first set broke in?

yes thats the case that the first set was in

i take it the stock 2.28 gears did fine?

stock gears did fine, also im running 40" MTR's with 4:10 gears and 7mgte engine.........  yes i know your immediate reaction will be to think that i was probly beating the hell out of it at 5000 rpm putting my 240 or so HP to full use against large tires and relatively high diff gears, BUT  like i said numerous times already, that was not the case! haha  Just idling up a log with one tire while i was all the way down in double low.

[pumkin toy [OP]]

http://board.marlincrawler.com/index.php?topic=78097.msg918917#msg918917

here pics of what im talking about.. they were missing (in these pics) on my case with m.c 4.7s. they were also missing in 5 other wheeling buddies rigs where i live. might not even be your issue at all but worth a check.

absolutely NONE of the snap rings or detent balls or anything like that were missing or slopping around.  There is no damage anywhere else in the case but the teeth that broke off the MC gears.  I do have quite a bit of experiance building dual case setups, so im familiar with all of the things that could go wrong during the assembly process.

[TURBO]

yeah i figured you knew what you were doing, i'm at a loss... my only explanation would be a bad lot of gears... sorry for making you repeat yourself so much LOL... i just really wanna know what's going on here is all...



VERY STRANGE...

[pumkin toy [OP]]

..... COMPLETELY TRUE... this is where i was headed with my line of questioning...

honestly i had pumkin toy figured for anything BUT a newbie, and the c- clip thing only breifly crossed my mind as something a newbie would do, but hey, i make stupid mistakes or over look things sometimes

very possible (considering how fast they broke after you got the new set)
missing c-clips on the input and counter shaft gears like "-Matt-" posted here--> http://board.marlincrawler.com/index.php?topic=78097.msg918917#msg918917

but if this was true, if you were going forward, the helical gears would cause the input to go towards the grill and the counter shaft towards the tailgate, am i Right? because i have seen on one occasion where the counter shaft has been pushed so far off the 63/32 bearing, it started milling away at the #2 housing and pushed the counter shaft cage bearing up against or (nearly up against) that ledge behind it but i believe (if my memory serve me right )the gears themselves were fine and practically untouched. i know for certain the small set of teeth on the counter were perfectly normal looking

this leads me believe it's more of an alignment issue, which is VERY rare in the RF1A Transfer Case, but helical gears by design can not take hardly any misalignment at all

so make sure both your dowl pins are there, not too deep...and TIGHT!!!... no wiggle wobble


also, as a side note, it's not a good idea to assemble a t-case with silicon. gaskets are a lot thicker than silicon (relatively speaking) and it CAN also create problems  inside the case, like oiling and tolerance issues... and don't use both! just make sure the gasket surfaces are completely oil free, brake clean and a rag should do it. sometimes people will take the front of the reduction (or #1) housing to a belt sander to true up the gasket surface... there by causing the input and counter gears to get closer to the #2 housing, tightening the tolerance between the main shaft, and the back of the input... i have seen those two surfaces come into contact before so it's not impossible but something to watch out for....(this is probably not YOUR issue but its good common knowledge)

I had issues with a case in the past where a snap ring wasnt installed and one of the gearsets was slopping back and forth.  no damage was eer caused to the gears.  The case was getting worn down from the gear grinding against one of the bearing surface areas but it neveer caused any damage to the teeth or anything like that.  I cant imagine that I have any alignment issues anywhere. Like i said noe of the housing areas have signs of gears slopping into them or rubbing together in places they shouldnt.  I have built multiple cases with silicone instead of gaskets, we used to buld them like that all the time when my dad owned his shop. We have never encountered an issue with any of the other cases we have built, so i cant imagine that silicone rather than a gasket is causing my gears to explode.  You can even see from the pics that the entire length of the broken gears is broken off. that tells me there are no alignment or gear mesh issues with the MC gears.  I simply think its a product failure.
Also you asked about how my case is mounted under the truck. I'm assuming you are wondering about the t-case housing itself taking stress in strange areas and possibly causing the gears to deflect from one another and cause premature failure?  I do have poly bushings at the framerails where the x-member  bolts into place.  its basically the same concept as  the FROR x-member.  I believe that if i was somehow having issues with the case taking strange stress from the mount,  then the t-case housing would simply crack and split apart before it caused the gears to fail.  I dont see how there could possibly be enough movement in the housing itself to allow the gears to deflect enough to break.
Also the back of the transmission is in perfect condition

[pumkin toy [OP]]

yeah i figured you knew what you were doing, i'm at a loss... my only explanation would be a bad lot of gears... sorry for making you repeat yourself so much LOL... i just really wanna know what's going on here is all...



VERY STRANGE...

I wanna know whats going on too!  I really appreciate the info and possibilities that you have presented though
I think just for good measure, i will also get 5:29 gears installed in the diffs before wheeling it again once the case is fixed

[TURBO]

i couldnt tell you what # the gearset is, i dont know where to find that out

it should be on the back of the input gear... i think i answered my own question after seeing a few pics... i think yours are like 4041T or something like that

[pumkin toy [OP]]

it should be on the back of the input gear... i think i answered my own question after seeing a few pics... i think yours are like 4041T or something like that

ok cool, i will check it out!

[TURBO]

I simply think its a product failure.
Also you asked about how my case is mounted under the truck. I'm assuming you are wondering about the t-case housing itself taking stress in strange areas and possibly causing the gears to deflect from one another and cause premature failure?  I do have poly bushings at the framerails where the x-member  bolts into place.  its basically the same concept as  the FROR x-member.  I believe that if i was somehow having issues with the case taking strange stress from the mount,  then the t-case housing would simply crack and split apart before it caused the gears to fail.  I dont see how there could possibly be enough movement in the housing itself to allow the gears to deflect enough to break

never crossed my mind but i completely agree... for whatever that's worth... i'm no expert

[TURBO]

I think just for good measure, i will also get 5:29 gears installed in the diffs before wheeling it again once the case is fixed

sounds like a good idea

[pumkin toy [OP]]

So I talked to Brendan at MC today and they are hooking me up with a replacement set of chromoly competition gears and a reduced price on the second set i need to buy!!   He thinks its just the combo of 4:10 gears and 40" tires that are eating up the t-case.  its awesome that he hooked me up with some cromoly gears! 

Thanks again Brendan, its greatly appreciated!

[Jaysen]

GO !!! That why you buy MC parts!!!!!

[46&2]

    

[83 Crawler]

GO !!! That why you buy MC parts!!!!!

amen to that

[pumkin toy [OP]]

So the new set of chromoly gears came in on thursday.  now im trying to find a buddy tha has a "clamshell" style bearing puller that i can use to get all my bearings swapped around and re-assemble the case.  hopefully i will be putting it back together next week sometime!

[minicrawlin]

paulie has one that douglas used i'm pretty sure . . . or maybe douglas has one . . . .hmmmm.  .. . ha ha   I think you just need front locker and to put the hammer down to hammer town more man. Good work MC for man N' up in the situation!

[Zs Confederate Toy]

Good to hear on the replacement gears. Very straight up business right there

[cen-cal crawler]

[quote :  He thinks its just the combo of 4:10 gears and 40" tires that are eating up the t-case.  its awesome that he hooked me up with some cromoly gears! 

whaaaa??? How does that feel like?:0

[pumkin toy [OP]]

[quote :  He thinks its just the combo of 4:10 gears and 40" tires that are eating up the t-case.  its awesome that he hooked me up with some cromoly gears! 

whaaaa??? How does that feel like?:0

what do you mean "how does that feel"?

Well i got the t case back together and everything ready to go!  Just gotta round up some more money to get my 5:29 gears put in

[Shamb]

curious to see how this new set of 4.7's holds up.

[19864runner]

Love this video of the 4runner in the snow and building up boost i hope to see another snow video like this with the 4runners new updates.
http://www.youtube.com/watch?v=S46MrntyU8M&feature=BFa&list=FLts8Lo0nPPHZPj3q5NWRxxg&lf=mh_lolz

[stormrunner]

that was a lot of reading but that 4runner has come a long way, favorite 4runner of all time, and man i think you have a stalker haha

[pumkin toy [OP]]

that was a lot of reading but that 4runner has come a long way, favorite 4runner of all time, and man i think you have a stalker haha

yeah its a long build thread!  Glad you like my runner!  yeah i would agree about the stalker situation, haha. 

I havnt worked on it for a while.  Got the new gears all installed and everything put back together. Now its sitting at a friends house in his garage. he is storing it for me while i do a bunch of fab work on his FJ-40 project.  doing a full cage, front and rear bumpers and tube fenders up front.

[pumkin toy [OP]]

So Its getting cold again and i havnt spent any time wheeling or working on my own rig lately.  im out of money to spend on my rig and thats basically what i need to move forward with it right now. So in hopes of paying off a few bills and getting some extra cash for my 4runner I am picking up some side jobs.  The big project right now is a friends 74 FJ-40.  This is his first ground-up build of a crawler and he has done everything himself so far.  Its to the point now where it needs alot of tubework and fab stuff done. he has hired me to do all of that stuff. Plans are a full cage with seat cradle and 4 point harnesses, front grille hoop/bumper/winch mount, front tube fenders, and a rear bump with swing out tire carrier. he also wants me to change around a couple things on the rear 4-link setup that he installed just to make sure its all legit and ready to go for spring. 

So far I have gotten the cage and seat cradle done. here are a bunch of pics!

[Uncle Ben]

Very nice Caleb!

[cen-cal crawler]

what do you mean "how does that feel"?

Well i got the t case back together and everything ready to go!  Just gotta round up some more money to get my 5:29 gears put in

I meant how does that drive like? i had 4:10 and 35 and it was horrible going uphill! I couldnt imagine 40's!

[Zs Confederate Toy]

Gotta love the hockey puck body lift. That how Im doin it to clear tires