ATL Cruiser
GOLD Star
My HZJ77 left me stranded a few months ago. The A440F automatic transmission blew up internally with zero line pressure.
I always felt that the automatic transmission robbed a lot of power. I mean, the thing is absolutely massive:
Instead of rebuilding the automatic unit, I decided to swap out for an H55F manual transmission. This turned out to be a major undertaking sourcing parts from around the world:
Grateful to @orangefj45 for sourcing the transmission and transfer case. Georg also installed a 10% higher final gear, which makes highway driving nicer. It all arrived in a mega crate in perfect condition. I ordered the correct bellhousing + both sets of dowels (trans side and engine side) and installed it.
CROSSMEMBER + GUSSETS
Upon installing the transmission, I realized that there was nothing to bolt the rear trans mount to. Toyota built two versions of the HZJ77 frame. One with automatic, one with manual. The manual transmission crossmember sits about 12" further forward:
I ordered the correct gussets + crossmember + trans mount and welded them in place. I highly recommend getting a level gage to set the correct driveshaft pinion angle before welding everything in place.
Klein 935DAGL is a great digital level tool for setting the pinion angle before welding in the gussets. If you have a lift on the rear, you will need to install leaf spring angle shims as well.
DRIVESHAFTS
The automatic and manual HZJ77's have different front and rear driveshaft lengths. Rough measurements:
TRANSFER LEVER
Since the transmissions are different lengths, the transfer case lever needed to be shortened. @cruisermatt sells these for the 60 and 70 series. It worked fantastic.
WIRING HARNESS
The manual transmission and automatic also have different wiring harnesses. @cruisermatt also sells and adapter harness which he sent. It fit and worked perfectly. I forgot to take a picture of the harness, but it's plug-and-play.
I always felt that the automatic transmission robbed a lot of power. I mean, the thing is absolutely massive:
Instead of rebuilding the automatic unit, I decided to swap out for an H55F manual transmission. This turned out to be a major undertaking sourcing parts from around the world:
- H55F transmission + transfer case
- Crossmember + gussets + mount
- Driveshafts
- Transfer lever
- Wiring harness
- Clutch pedal
- Clutch hydraulics
- Shift console
- Carpet
- Shift knobs
- Shift lever
Grateful to @orangefj45 for sourcing the transmission and transfer case. Georg also installed a 10% higher final gear, which makes highway driving nicer. It all arrived in a mega crate in perfect condition. I ordered the correct bellhousing + both sets of dowels (trans side and engine side) and installed it.
CROSSMEMBER + GUSSETS
Upon installing the transmission, I realized that there was nothing to bolt the rear trans mount to. Toyota built two versions of the HZJ77 frame. One with automatic, one with manual. The manual transmission crossmember sits about 12" further forward:
I ordered the correct gussets + crossmember + trans mount and welded them in place. I highly recommend getting a level gage to set the correct driveshaft pinion angle before welding everything in place.
Klein 935DAGL is a great digital level tool for setting the pinion angle before welding in the gussets. If you have a lift on the rear, you will need to install leaf spring angle shims as well.
DRIVESHAFTS
The automatic and manual HZJ77's have different front and rear driveshaft lengths. Rough measurements:
- Front driveshaft (automatic): 798mm (31 7/16")
- Rear driveshaft (automatic): 968mm (38 1/8")
- Front driveshaft (manual): 679mm (26 3/4")
- Rear driveshaft (manual): 1108mm (43 5/8")
TRANSFER LEVER
Since the transmissions are different lengths, the transfer case lever needed to be shortened. @cruisermatt sells these for the 60 and 70 series. It worked fantastic.
WIRING HARNESS
The manual transmission and automatic also have different wiring harnesses. @cruisermatt also sells and adapter harness which he sent. It fit and worked perfectly. I forgot to take a picture of the harness, but it's plug-and-play.
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