My H55F/Toybox install thread

CaliCruiser · 06-08-08, 09:58 AM

It's coming down to the wire for Rubithon, so I figured if I started this thread I would push harder to get it done. The h55f/toybox/split case is fully assembled. I need to split it apart one more time to apply some grey silicone between the h55f and toybox.

Yesterday I modified the factory transmission cross member to clearance the front drive shaft.

I bent up some 1/4" x 5" flat plate steel for the new cross member piece.

I ran a grinder along the cut lines and then bent the sheet in a vice to keep it one piece. It is a lot simpler than tacking three individual pieces together and keeping them square.

First side ground out and ready.

both sides mocked up.

Internal seems welded up.

Gussets on the outside .

Welded up the entire thing. Let it cool. Then cut out the factory piece of the cross member. The finished product.

Butt Ugly Chuck · 06-08-08, 10:01 AM

Nice fab work!

Butt

CaliCruiser · 06-08-08, 10:02 AM

Todays project is the twin sticks for the split case. I should have some pictures of that tonight. If I finish that then I'll pull the center console and mock up where the hole for the toybox shifter will come through.

Here is a shot of the assembled Toyota gears.

klinetime574 · 06-08-08, 10:25 AM

Dang Dylan.

I'm drooling. Nice Fab work

mel lowe · 06-08-08, 12:16 PM

Ding dong dang!

Awesome set up

Dirtgypsy · 06-08-08, 12:22 PM

I love it. Do you have a thread of the issues of putting it together?

Also could you measure the distance between the shifters?

Rock on bro,

clint

CaliCruiser · 06-08-08, 09:44 PM

Ok twin sticks are 85% done. I still need to crawl underneath and check out how the tunnel slopes so I can figure out the angle for the actual shift lever. It may not look like much, but this took a really long time and ate most of the day.

Here they are mocked up on the bench.

I didn't like the angle of the right hand linkage so I ended up cutting it up and reseting it closer to the inside piece.

I pulled off the hi/lo lever and ground a flat spot 90 degrees from the factory flat spot to move the lever. Now it operates in the forward-backward direction as opposed to the side to side factory movement. If you do this make sure when you pull the lever of, that you clamp a vice grip onto the shaft, otherwise that shift rail can FALL INTO THE SPLIT CASE and you have to pull the case apart.

Here are few shots of the linkage mocked up. The threaded rod will get jam nuts up against the heim joints and the brackets will get painted.

CaliCruiser · 06-08-08, 10:06 PM

Quote:

Originally Posted by Dirtgypsy

I love it. Do you have a thread of the issues of putting it together?

Also could you measure the distance between the shifters?

Rock on bro,

clint

No, I didn't start a thread on the assembly because I ended up not doing that part of it myself. I attempted to do it, but there were simply to many variables to get 100% correct. I can say that Marlin is aware of the entire assembly process now, because he did this one. I'll save the details for Marlin to disclose, he took lots of pictures and I *think* plans on making some instructions. PM if you have any specific questions.

I'll grab the shifter measurement tomorrow after work, when I'm back in the shop. Thanks for comments guys. Lemme know if anything looks funky.

Dylan

Cruiserdrew · 06-08-08, 10:10 PM

Daaaaamn. Good work. So is it in yet?

keep it coming. Looking forward to how it all goes.

See you next week.

edit: will you do my cross-member?

CaliCruiser · 06-08-08, 10:30 PM

Ya I just picked it up and walked it over to my 60 and threw it in

I need to get it in by Tuesday or so, to measure for drive shafts and maybe take it for a quick spin on the weekend.

I still need to:

-complete twin sticks
-cut a hole for the toybox shifter
-install it
-find a boot for the toybox shifter
-find someone that has a twin stick boot in stock
-drive shafts
-clearance the area around the transfer case at the back of the tunnel

. . .thats enough to think about

Dylan

chicago · 06-08-08, 11:34 PM

Bad ass big D!
Youve done a beautiful job man!

Chicago

chappysfj40 · 06-08-08, 11:42 PM

what run you on? iam on the wagon run see you on the trail reguard less
great work

NocalFJ60 · 06-09-08, 12:03 AM

Awesome work Dylan. I like how your crossmember turned out. Try Marlin on the toybox shift boot.

LCOwner · 06-09-08, 10:08 AM

Quote:

Originally Posted by CaliCruiser

-find a boot for the toybox shifter
-find someone that has a twin stick boot in stock

Marlin has both.

GLTHFJ60 · 06-09-08, 03:55 PM

That is exactly the set up I plan on running in my rig some day. Beautiful work, and I can't wait to see it all buttoned up!

CaliCruiser · 06-09-08, 06:41 PM

Quote:

Originally Posted by LCOwner

Marlin has both.

Oh, I didn't see the twin stick boot on their website. The single is 55 bucks? Ouch, I am out of cash. It may be a boot-less Rubithon, hopefully the water isn't too deep.

Dylan

Dirtgypsy · 06-09-08, 08:40 PM

nice work here is an alternative. not bashing marlin's stuff but these are very well made:

JB Custom Fabrication: Shifter boots

clint

CaliCruiser · 06-09-08, 09:55 PM

Thanks for the link Clint. Center to center on the shifters came out to be about 11 and 1/4".

Dirtgypsy · 06-10-08, 10:44 AM

your welcome and thanks for the measurment.

clint

weak-link · 06-10-08, 11:18 AM

done yet?

CaliCruiser · 06-11-08, 11:41 PM

Ok, I just got in from installing the transmission and crossmember. I just was not up to installing the toybox-split case setup so that is going to happen tomorrow night. Now that the transmission is in I can get the angle of the twin stick shift lever. I figured I better wait so I didn't weld them on at the wrong angle. I don't have any pictures because my dad has the camera but proof will come tomorrow night.

Dylan

DBOZ40 · 06-12-08, 08:25 AM

Did you have to grind the bell housing, or did the H55 slide right in?

CaliCruiser · 06-12-08, 09:48 AM

Wow that is funny you asked that, almost like you were underneath it too when I realized I forgot to grind out a spot for the new wider h55f front cover plate.

Dylan

chicago · 06-12-08, 11:48 AM

Dude...
I might be hitting you up with the x member and linkage fab for mine when the time comes!
That came out really frickin awesome!
Cant wait to see the completed pics!
Im a bit nervous as to how my set up is gonna come together when I have all the pieces in place!

Chicago

vipergrhd · 06-12-08, 05:48 PM

that thing looks killer man,wish i could weld like that.

john

CaliCruiser · 06-14-08, 01:46 AM

IT'S IN!!!!!!!!!!!!!!!!!!

The drive train is fully assembled an installed. It is definitely a tight fit, but everything fits with a little clearance. I do not have a body lift so that made the install even a bit more challenging. After I spent a bunch of time trying to install it with the transmission and crossmember installed, I ended up pulling the crossmember and letting the transmission droop down a bit to give me a better approach angle into to align the output shaft and input coupler. I'm tired so here are some pictures. . .

Cruiserdrew · 06-14-08, 06:19 AM

Awesome-so we'll see you Wednesday morning.

Where did you get that output flange for the t-case? It does not look stock.

Does it really fit without hitting the body at the back of the tunnel?

06-08-08, 09:58 AM	#1
CaliCruiser IH8MUD Lifer Join Date: Aug 2005 Location: Pine Grove, Ca TLCA# 15987 Posts: 1,803	My H55F/Toybox install thread It's coming down to the wire for Rubithon, so I figured if I started this thread I would push harder to get it done. The h55f/toybox/split case is fully assembled. I need to split it apart one more time to apply some grey silicone between the h55f and toybox. Yesterday I modified the factory transmission cross member to clearance the front drive shaft. I bent up some 1/4" x 5" flat plate steel for the new cross member piece. I ran a grinder along the cut lines and then bent the sheet in a vice to keep it one piece. It is a lot simpler than tacking three individual pieces together and keeping them square. First side ground out and ready. both sides mocked up. Internal seems welded up. Gussets on the outside . Welded up the entire thing. Let it cool. Then cut out the factory piece of the cross member. The finished product. __________________ ROTW '85 FJ60 \| SOA \| ARB \| M8274-50 \| Sliders \| Aussie'd \| H55F \| 4.7 Toybox \| 4.88s \| Custom Crap

06-08-08, 10:01 AM	#2
Butt Ugly Chuck IH8MUD Regular Join Date: Jan 2007 Location: Arcata, CA TLCA# 18371 Posts: 329	Nice fab work! Butt __________________ 7/85 FJ60 261k miles 91 Haro Extreme AL MTB - daily rider 16' Aire Jaguarundi

06-08-08, 10:02 AM	#3
CaliCruiser IH8MUD Lifer Join Date: Aug 2005 Location: Pine Grove, Ca TLCA# 15987 Posts: 1,803	Todays project is the twin sticks for the split case. I should have some pictures of that tonight. If I finish that then I'll pull the center console and mock up where the hole for the toybox shifter will come through. Here is a shot of the assembled Toyota gears. __________________ ROTW '85 FJ60 \| SOA \| ARB \| M8274-50 \| Sliders \| Aussie'd \| H55F \| 4.7 Toybox \| 4.88s \| Custom Crap

06-08-08, 10:25 AM	#4
klinetime574 IH8MUD Regular Join Date: Jul 2006 Location: Belton, Texas Posts: 450	Dang Dylan. I'm drooling. Nice Fab work __________________ 1984 FJ60, 170 Thousand Miles, OME, 33x10.5x15 BFGoodrich All-Terrain T/A KO, 15x8 Eagle 058 Alloys

06-08-08, 12:16 PM	#5
mel lowe IH8MUD Lifer Join Date: May 2005 Location: The Sunshine State Posts: 1,648	Ding dong dang! Awesome set up __________________ 82 Fj60 TurkeyWizz THXAL 88 BJ62 Family Truckster http://nfcruiserheads.org/forum/index.php

06-08-08, 12:22 PM	#6
Dirtgypsy IH8MUD Addict Join Date: May 2006 Location: Newberg, Oregon TLCA# 17541 Posts: 854	I love it. Do you have a thread of the issues of putting it together? Also could you measure the distance between the shifters? Rock on bro, clint __________________ It's a Jeep thing I didn't understand. So I bought an FJ60 and now I get it. 1987 FJ60, 2F, H55F, 4.11's, Rear ARB locker, ARB bumper, MAF Safari 4" SR, 33 12.50 15 on old school Mags. ROTW: http://forum.ih8mud.com/60-series-wa...lver-60-a.html

06-08-08, 09:44 PM	#7
CaliCruiser IH8MUD Lifer Join Date: Aug 2005 Location: Pine Grove, Ca TLCA# 15987 Posts: 1,803	Ok twin sticks are 85% done. I still need to crawl underneath and check out how the tunnel slopes so I can figure out the angle for the actual shift lever. It may not look like much, but this took a really long time and ate most of the day. Here they are mocked up on the bench. I didn't like the angle of the right hand linkage so I ended up cutting it up and reseting it closer to the inside piece. I pulled off the hi/lo lever and ground a flat spot 90 degrees from the factory flat spot to move the lever. Now it operates in the forward-backward direction as opposed to the side to side factory movement. If you do this make sure when you pull the lever of, that you clamp a vice grip onto the shaft, otherwise that shift rail can FALL INTO THE SPLIT CASE and you have to pull the case apart. Here are few shots of the linkage mocked up. The threaded rod will get jam nuts up against the heim joints and the brackets will get painted. __________________ ROTW '85 FJ60 \| SOA \| ARB \| M8274-50 \| Sliders \| Aussie'd \| H55F \| 4.7 Toybox \| 4.88s \| Custom Crap

06-08-08, 10:10 PM	#9
Cruiserdrew KI6MIE Join Date: Mar 2003 Location: Sacramento, CA TLCA# 11734 Posts: 6,975	Daaaaamn. Good work. So is it in yet? keep it coming. Looking forward to how it all goes. See you next week. edit: will you do my cross-member? __________________ Andrew 1971 FJ-40 Rubicon tested, 2F powered, some mods 1976 FJ40 Rusting slowly in the back yard 1984 FJ-60 H55f, 4.11, OME, Daily Driver 1989 FJ-62 117k-son's driver for now-low and slow 1997 FZJ-80 Driveway queen

06-08-08, 10:30 PM	#10
CaliCruiser IH8MUD Lifer Join Date: Aug 2005 Location: Pine Grove, Ca TLCA# 15987 Posts: 1,803	Ya I just picked it up and walked it over to my 60 and threw it in I need to get it in by Tuesday or so, to measure for drive shafts and maybe take it for a quick spin on the weekend. I still need to: -complete twin sticks -cut a hole for the toybox shifter -install it -find a boot for the toybox shifter -find someone that has a twin stick boot in stock -drive shafts -clearance the area around the transfer case at the back of the tunnel . . .thats enough to think about Dylan __________________ ROTW '85 FJ60 \| SOA \| ARB \| M8274-50 \| Sliders \| Aussie'd \| H55F \| 4.7 Toybox \| 4.88s \| Custom Crap

06-08-08, 11:34 PM	#11
chicago IH8MUD Lifer Join Date: Jan 2006 Location: Reno, Nevada Posts: 3,119	Bad ass big D! Youve done a beautiful job man! Chicago __________________ TLCA#16202, KE7VAT Toyota family: 88 FJ62 (Fairly built) 06 4runner...wifes rig! 06 Tacoma, DD, BONE STOCK and staying that way! PROUD member of the WEST COAST BLOTCHERS and the Battle Born Cruisers of Northern Nevada! FAWKING CUBS! Life long DISAPPOINTMENT!

06-08-08, 11:42 PM	#12
chappysfj40 IH8MUD Regular Join Date: Mar 2004 Location: PORT HUENEME , CA TLCA# 9188 Posts: 484	what run you on? iam on the wagon run see you on the trail reguard less great work __________________ - Iam home now from the SUCK !!!!!!! VJ60 700R4 33's 203 doubler, ARB's 4.56, OME and just a awesome truck!!!!!!!!!! - RUBITHON 2008 TESTED GOD ASKED FOR 10 DAYS TO CREATE EARTH, CHUCK NORRIS GAVE HIM 7..

06-09-08, 12:03 AM	#13
NocalFJ60 IH8MUD Lifer Join Date: Aug 2004 Location: San Francisco Bay Area Posts: 2,752	Awesome work Dylan. I like how your crossmember turned out. Try Marlin on the toybox shift boot. __________________ 1982 FJ60 Northern California TLCA/PMC Member "He who throws mud only loses ground."

06-09-08, 08:40 PM	#17
Dirtgypsy IH8MUD Addict Join Date: May 2006 Location: Newberg, Oregon TLCA# 17541 Posts: 854	nice work here is an alternative. not bashing marlin's stuff but these are very well made: JB Custom Fabrication: Shifter boots clint __________________ It's a Jeep thing I didn't understand. So I bought an FJ60 and now I get it. 1987 FJ60, 2F, H55F, 4.11's, Rear ARB locker, ARB bumper, MAF Safari 4" SR, 33 12.50 15 on old school Mags. ROTW: http://forum.ih8mud.com/60-series-wa...lver-60-a.html

06-09-08, 09:55 PM	#18
CaliCruiser IH8MUD Lifer Join Date: Aug 2005 Location: Pine Grove, Ca TLCA# 15987 Posts: 1,803	Thanks for the link Clint. Center to center on the shifters came out to be about 11 and 1/4". __________________ ROTW '85 FJ60 \| SOA \| ARB \| M8274-50 \| Sliders \| Aussie'd \| H55F \| 4.7 Toybox \| 4.88s \| Custom Crap

06-10-08, 10:44 AM	#19
Dirtgypsy IH8MUD Addict Join Date: May 2006 Location: Newberg, Oregon TLCA# 17541 Posts: 854	your welcome and thanks for the measurment. clint __________________ It's a Jeep thing I didn't understand. So I bought an FJ60 and now I get it. 1987 FJ60, 2F, H55F, 4.11's, Rear ARB locker, ARB bumper, MAF Safari 4" SR, 33 12.50 15 on old school Mags. ROTW: http://forum.ih8mud.com/60-series-wa...lver-60-a.html

06-12-08, 05:48 PM	#25
vipergrhd IH8MUD Regular Join Date: May 2007 Location: no.california S.F.O BAY AREA (EAST BAY) Posts: 437	awesome job that thing looks killer man,wish i could weld like that. john __________________ If i can't fix it i don't buy it.if it cost too much to fix then trash it. 87 fj60 mostly stock at this time 93 toy hi-lux 4x4 extra cab w/camper shell also stock 95 mitsu montero sr w/ rear lockers (wife's suv) 99 mitsu galant gtz (wife's DD)

06-10-08, 11:18 AM	#20
weak-link IH8MUD Addict Join Date: Jul 2005 Location: Fresno,ca Posts: 752	done yet? __________________ www.4x4Him.com Pit Bull Rescue Central http://www.pbrc.net/

06-11-08, 11:41 PM	#21
CaliCruiser IH8MUD Lifer Join Date: Aug 2005 Location: Pine Grove, Ca TLCA# 15987 Posts: 1,803	Ok, I just got in from installing the transmission and crossmember. I just was not up to installing the toybox-split case setup so that is going to happen tomorrow night. Now that the transmission is in I can get the angle of the twin stick shift lever. I figured I better wait so I didn't weld them on at the wrong angle. I don't have any pictures because my dad has the camera but proof will come tomorrow night. Dylan __________________ ROTW '85 FJ60 \| SOA \| ARB \| M8274-50 \| Sliders \| Aussie'd \| H55F \| 4.7 Toybox \| 4.88s \| Custom Crap

06-12-08, 08:25 AM	#22
DBOZ40 IH8MUD Junior Join Date: Dec 2006 Location: Pine Grove, CA Posts: 92	Bell Housing Did you have to grind the bell housing, or did the H55 slide right in? __________________ '78 Fj40

06-12-08, 09:48 AM	#23
CaliCruiser IH8MUD Lifer Join Date: Aug 2005 Location: Pine Grove, Ca TLCA# 15987 Posts: 1,803	Wow that is funny you asked that, almost like you were underneath it too when I realized I forgot to grind out a spot for the new wider h55f front cover plate. Dylan __________________ ROTW '85 FJ60 \| SOA \| ARB \| M8274-50 \| Sliders \| Aussie'd \| H55F \| 4.7 Toybox \| 4.88s \| Custom Crap

06-12-08, 11:48 AM	#24
chicago IH8MUD Lifer Join Date: Jan 2006 Location: Reno, Nevada Posts: 3,119	Dude... I might be hitting you up with the x member and linkage fab for mine when the time comes! That came out really frickin awesome! Cant wait to see the completed pics! Im a bit nervous as to how my set up is gonna come together when I have all the pieces in place! Chicago __________________ TLCA#16202, KE7VAT Toyota family: 88 FJ62 (Fairly built) 06 4runner...wifes rig! 06 Tacoma, DD, BONE STOCK and staying that way! PROUD member of the WEST COAST BLOTCHERS and the Battle Born Cruisers of Northern Nevada! FAWKING CUBS! Life long DISAPPOINTMENT!

06-14-08, 01:46 AM	#26
CaliCruiser IH8MUD Lifer Join Date: Aug 2005 Location: Pine Grove, Ca TLCA# 15987 Posts: 1,803	IT'S IN!!!!!!!!!!!!!!!!!! The drive train is fully assembled an installed. It is definitely a tight fit, but everything fits with a little clearance. I do not have a body lift so that made the install even a bit more challenging. After I spent a bunch of time trying to install it with the transmission and crossmember installed, I ended up pulling the crossmember and letting the transmission droop down a bit to give me a better approach angle into to align the output shaft and input coupler. I'm tired so here are some pictures. . . __________________ ROTW '85 FJ60 \| SOA \| ARB \| M8274-50 \| Sliders \| Aussie'd \| H55F \| 4.7 Toybox \| 4.88s \| Custom Crap