60 series transfer case with integrated Fairey overdrive

[AussieKymbo]

G'day. Im new here but hoping to gather as much information on what I was told is a rare Toyota transfer case as I can get!

What I have is a transfer case that has come from a FJ60 2F 4 speed. I got the vehicle purely because it had a Fairey Overdrive in it.

However, when I picked it up, I looked under and to my surprise, there was NO Fairey overdrive of the type I was familiar with .

The type I am familiar with and know about is the separate Fairey unit that bolts onto the back of the transfer case .

This transfer case is longer toward the back, and houses the Fairey overdrive Inside the transfer case with the overdrive selector leaver mounted to the top bolts that attach the transfer case to the gearbox.

On calling a mate who wrecks a few Landcruisers he told me he knew of these but hadn't seen any and felt it was a rare transfer case that Toyota made prior to the 5 speed gearbox being introduced but after the 55 which also used the bolt on Fairey overdrive on it if fitted, other models also used the Fairey overdrive .

My aim is to attach this transfer case to my HJ60 2H 5 speed gearbox to enable me to split each gear as I tow a 22 foot caravan.

I'm after ANY information at all on these transfer cases, also what if any problems others feel I will or may encounter putting this transfer case WITH integrated Fairey overdrive onto my 5 speed gearbox.

 

[inkpot]

Howdy! This sounds like a unit I saw advertised years ago. It was a replacement rear section for the split case transfer. It was much deeper so it could carry an extra row of gears inside to operate as an Overdrive. Don't remember the name, yet, but I'm working on it. It was heavily advertised for a few years in the USA 4x4 magizines, and I think one of them did a tech article about installation. IIRC, it was an Australian product. John

 

[stockhorse]

G'day Kymbo. they are stonger than the "add on " fairey overdrives and are fairly hard to come by.I would not advise trying to use it as a splitter for each gear unless you have 3 arms.

Remember this is an overdrive. so you need to go 1st gear take off, then use fairy to go to 1st0ver.(it is not a half gear)by moving the fairey to engage.. Then to change to second you need to change from 1st to 2nd gear and at the same time, move the fairy lever to disengage.Then go from 2nd to 2ndOver with the fairey and etc through to 4thover then 5th. You don't really want to use 5th gear when towing but certainly wouldn't use 5th over as you are using overdrive on an overdrive and the 2h would be well below its torque range and wouldn't go anywhere.
While it may seem like a good idea it really isn't.
What weight is the 22 ft van? Will the 2h pull it with reasonable acceleration and hill climbing ability with the standard 5 speed ?
The 2h is not a speedster as you know so adding 2 tonne to it by way of a caravan is asking a lot from it. You may be better spending your time fitting a turbo to it at 9-10 boost it will be far nicer to drive than non turboed with fairey.

.

 

[60Works]

They're rare because they don't last all that long. Last I checked, 2+ years ago, Rovers South still had a few units new in the box. Parts are utterly unavailable. I pulled mine out several years ago.

Use the Fairey as a 5th gear and don't shift it if you don't have to. Downshift when stopped. It is possible to downshift on the fly if you double clutch but the unit doesn't like it. The shift forks and syncros failed in mine in less than 100k miles.

An H55 5-speed is a much better solution to gain on overdrive. The third gear stick is pretty cool though. And having a reverse overdrive was also surprisingly handy.

I think I still have the installation instructions buried in storage somewhere. If I haven't posted them in a week PM me and remind me.

 

[AussieKymbo]

Hey thanks for the info Inkpot, Stockhorse and Juggernaught.

Juggernaught I am hoping you can find the instructions etc for this specific transfer case. I do have 3 manuals for the common Fairey overdrive, but still as yet nothing on this integrated Fairey transfer case. Yes Rovers Down South stopped all Fairey production back in December 2011, still have some spares available but no units and some spares are NLA.

I will clarify that Im definately not intending to use it as a splitter between every gear, that's pointless and a waste of time. As stated, I tow a 22 foot caravan. When I need a gear ratio that's not available in the 5 speed, (the gear ratios are so wide apart in these boxes when it comes to towing something heavy) Id be using the Fairey as a spliter ONLY then, mostly will happen between 3rd/4th and on occasion between 2nd/3rd, but it will only be used when needed, not to show off and make it sound like a 10 speed gearbox.

On the 3rd shifter bit, I have onboard air and Im actually considering converting it to regulated air shift to be "selected as needed" off the main shifter, this will negate me needing the 3rd shifter lever. This if it happens would set it up with a return spring so IF the air shift fails in any way, it auto returns to the normal direct drive, not the OD mode..

Yes the transfer case is wider in the back half yes. When looking at it from the side, the normal narrow PTO cover is much wider, almost but not square and has all the Fairey Superwinch info and where its made cast into that larger plate, and this plate on the inside holds the overdrive idler gear.

Stockhorse, the 22 foot Caravan is quite heavy, I dont know exact weight. It's a full size caravan, holds 270 litres of water in 2 tanks, 3kva generator, full sized Waeco fridge, shower toilet etc etc and I carry comprehensive spares in it as well, as Aust is HUGE and can be long distances between towns or help and isolated as we know. The 2H is also turbo'd & intercooled, it goes well and as you say, not a speedster, I like to take my time and "smell the coffee n roses" while I travel as well.

Ive traveld extensively through eastern Australia and South Australia with it and the Landcruiser, the 2H pulls it well, isnt fast but 2H's were never known for speed "its a 2H, it wont get me there fast, but it WILL get me there", LOL. Check my website. It towed very well up through the Blue Mountains / Great Dividing Range, again, not fast but did it with ease. I have a short vid on my setup coming through on a flooded road and doing it well, http://www.aussiekymbo.com/videos.html .

My only issue is that the ratios with the 5 speed are too wide, which again is why I want to use this transfer case as a splitter more than an actual final overdrive

I do "collect" Fairey overdrives so have a limited supply of spare parts in emergencies, lol.

Thanks again and Im mpore than open to more info and thoughts on all of this.

Kymbo

 

[ozwallaby]

I almost called b/s on this (I've never seen or heard of these INTERNAL overdrives for cruisers) but it seems it has some support from other mudders... how 'bout a few pix...

 

[sved]

I have a original manual ''fairey overdrive for toyota landcruiser'' .
The manualnumber is 6810.Issue 3/84
It discribes how to replace the backpart of the transfercase and replace it with the fairey transfer backpart.
This can be done on 4speed and 5 speed gearboxes in 40 and 60 series.
Overdrive ratio is 078:1
Is this what you are looking for?

Many many moons ago i had this installed on a '84 BJ42 5 speed.
This created like you said 10 forward gears (HI and Lo) and two reverse.

If i remember correctly, it created the effect, that if you activated the overdrive between say 2nd and 3rd gear you ended up with a higher endratio then the standard 3rd gear.

Let me know if it is what you are looking for then i can sent you a copy.

 

[60Works]

I was unable to find the installation manual. Sorry. It must have been in the box when I recycled the take out unit. Looks like Sved is coming to the rescue though.

A rear output bearing shim and a window sticker are the only evidence of existance I can provide. IIRC the yellow shim was to be used with new bearings. A red shim was used with reused bearings, which I did. The red plastic shim cracked and started leaking within a few thousand miles.



Toyota shims would probably work as would the case half's gasket. The upper idle gear cluster's seal was only silicone. I don't recall there even being a gasket in the kit.

Overall the unit was cool but disappointing. I wouldn't go to the effort of moving it to another transmission. I don't think it will handle the heavy loading you're intending. Your air activated spring return idea is clever but might not do the trick long term. When my OD failed it kept popping out of gear. I had to hold the shift lever hard in place to keep it from slipping into neutral. Any heavy engine load or relenting of pressure and it would buzz and slip.

IMHO, if you need the gear spacing in order to tow, then you are towing too much weight. I've pulled campers, boats, U-Hauls, and even another 60 with my 60 riding on 32's and 3:73's and it managed. Braking is not remotely safe with a heavy load, even with trailer brakes, and especially the inertia activated hitches.

Have fun but be smart. Good luck.

 

[AussieKymbo]

Thanks Blokes.

LOL ozwallaby, yeah probably a month ago I would have been sceptical at the very least if someone had told me of this, I have known, researched and collected Fairey overdrives for some time now, not a great deal I'm not familiar with about them but Id never claim to know everything about them, and this setup was and still is a 1st for me, can you imagine for a second the look on my face and what was firing in my brain when I looked under this FJ60 and saw NO Fairey overdrive attached to the normal place on the back of the transfer case, but inside, a 3rd gearshift and Id moved it so I knew it was connected to something, then on calling my mate, he confirmed to me that he had heard of these but not seen any. I have some pics of 1 on a 5 speed box, which is what I will do to mine eventually, Hopefully the pic has uploaded.

I do now have the gearbox/transfer case combo out of the vehicle and on my work bench and I'll be dismantling it as soon as I can and when Im back home again, ATM Im out doing a promotion for my invention.

juggernaught, its all good mate, thanks for searching anyway. Mate the 60 pulls the setup really well, its just up some hills and into strong head winds where there needs to be another ratio. The vehicle and caravan perform well, and stop well, electric brakes on both axles of the caravan and weight is all legal with no overloads etc

sved, I would really appreciate a copy what you have got, sounds interesting to say the least, doesn't matter if its either Fairey OD, I'll accept any and all literature, websites and or information. I have thought that IF engaging the OD on say 2nd gear (or any gear really) and it throws me above normal 3rd gear, its just a matter of using the OD in 1st to throw me between 2nd/3rd. This is just an EXAMPLE ONLY and ratios will be worked out once its set up and working etc.

Thanks again everyone, the input is very much appreciated.



Kymbo

 

[sved]

Aussiekymbo you are lucky, because now that i see your pictures i know for sure that the i have the manual that covers the overdrive that is attached to your transfer.
Yes, i also had this 3rd gearstick in my BJ42.It sat on the same position.
The only problem i had with the overdrive in the BJ42 was that it is longer then the original transfercase.This caused the casting to touch the fuel tank sometimes ,which resulted in some irritating noises and vibrations.You will not have this problem in a 60 series.

You want me to sent the copy (PDF) to you,then pm me your mailadres.Here's a preview i scanned

 

[AussieKymbo]

Hello Sved. YES, this is exactly the sort of item and literature Im looking for. I'll PM you with email etc, Cheer's
Kymbo

 

[sved]

You got mail

 

[AussieKymbo]

Thank you Sved, Im just looking at it now, this is great, I cant thank you enough, cheer's, Kymbo

 

[vanisl4runner]

I have been in search of any fairey over drive to fit my bj42 4 speed. If any of you know where one is available please please contact me

 

[SteveH]

Here's one, and I recall seeing a writeup in Four Wheeler magazine many years ago.

http://cosprings.craigslist.org/pts/4099625722.html

 

[Jed]

Aussiekymbo you are lucky, because now that i see your pictures i know for sure that the i have the manual that covers the overdrive that is attached to your transfer.
Yes, i also had this 3rd gearstick in my BJ42.It sat on the same position.
The only problem i had with the overdrive in the BJ42 was that it is longer then the original transfercase.This caused the casting to touch the fuel tank sometimes ,which resulted in some irritating noises and vibrations.You will not have this problem in a 60 series.

You want me to sent the copy (PDF) to you,then pm me your mailadres.Here's a preview i scanned

Hello sved,
I am in a similar predicament as my Aussie bro. Aussiekymbo,
I have a troopy with a 5 speed and am looking to mate a farey from a 4 speed onto the back of my 5 speed.
Would you be able to post that manual to me as well?
Cheers,
jed

 

[AussieKymbo]

Gday Jed. What version of the Fairey overdrive are you looking to put in. There are 3 by Fairey and 1 that is very similar to a Fairey that's made in Spain, called a "Toro" making 4 different versions all up. I have been collecting Fairey OD's for a while. The 3 versions are, this integrated version that's part of the Land Cruiser transfer case. The smaller bolt on version that bolts onto the plate that allows access to the gearbox output shaft. Then there is 1 made in Australia under licence by Fairey (Superwinch England) that has a larger finned oil sump which holds more oil than the original 1, more suited to Australia, and then the Toro version that has slightly larger bearings gears and oil capacity, similar to the Aussie made Fairey. I also have Sven's manual. Cheer's

 

[sved]

Hey Jed,
I have the manual in my home PC but i can't send it before i"m home sunday.Or kymbo has to be willing to send you a copy.
Cheers

 

[Jed]

Gday Jed. What version of the Fairey overdrive are you looking to put in. There are 3 by Fairey and 1 that is very similar to a Fairey that's made in Spain, called a "Toro" making 4 different versions all up. I have been collecting Fairey OD's for a while. The 3 versions are, this integrated version that's part of the Land Cruiser transfer case. The smaller bolt on version that bolts onto the plate that allows access to the gearbox output shaft. Then there is 1 made in Australia under licence by Fairey (Superwinch England) that has a larger finned oil sump which holds more oil than the original 1, more suited to Australia, and then the Toro version that has slightly larger bearings gears and oil capacity, similar to the Aussie made Fairey. I also have Sven's manual. Cheer's

G'day AussieKymbo, I have the Integrated version. It looks pretty much the same as the one you posted a picture of. I have 2 in fact. Both have the number 6337 cast into it.

 

[FJ40Jim]

The FOD that replaces the entire back half of the case is (obviously) intended for use in 81-later Cruisers with the split case and 19spline. The small planetary OD that goes on the rear PTO cover is used on the 10 spline and 16 spline trannies with one-piece case.

The split case FOD comes in 2 basic variants: 34mm or 38mm idler shaft. If your FOD was originally fitted to a 84-earlier split case w/ 34mm idler, and it's being moved to an 85-later transfer case with 38mm idler, then it will be necessary to swap over the matching front half of the transfer case as well.

HTH