Advice needed for custom 76' FJ40 (1 Viewer)

[jkravito]

Good afternoon everyone,
I recently purchased a 76" FJ40 that was someones project vehicle. It has an LT1 block, rebuilt Th350/NP205, narrowed Dana 60 rear (On Center) with a detroit locker and drum brakes, narrowed and offset Dana 60 front axle housing with 3rd member (Minus axle shafts). The front housing has also been retrofitted with Toyota knuckles and front disc brakes. So here is where my problems begin. The NP205 transfer does not hang out enough or low enough to allow proper front driveshaft clearance along the wide tranny pan on the TH350. I can improve the clearance by running a spring over setup but it will make this truck incredibly high and tipsy and in doing so I would probably need a rear driveshaft with an extra joint. I am looking for some ideas of possible alternate tranny/transfer arrangements to alleviate this problem or ideas on using some other parts I have in the garage. I have a set of FJ40 axles that only have 50k on them and a transfer case from the same 1977 FJ40 as well if that helps with some additional possibilities. Any ideas will be greatly appreciated as this is my first fairly custom FJ. Thanks a million

 

[cruiserrg]

Well I am assuming its a factory 350 to NP205 adapter which is long and has a drive sleave with 27 male NP205 input. I would look at replacing the adapter with a NP203 GRB and have it made so you can clock the NP205 or rotated to allow for more clearance and it would be a hair longer to give you more room and added bonus of better gearing (NP205s are ~2:1 in low). You could also consider a 2 peice front shaft to snake around the transmission. I think with most transfercases you are going to be close to the pan, it just depends on where it is clocked.

 

[jkravito]

Sounds like rotating the transfer is a good option. As I am new to this, are there companies that sell the parts for this modification? By clocking the transfer case on a new adapter, what internal components need to be replaced or modified?

 

[cruiserrg]

Good information on NP205s and NP203/205 doublers here: http://www.offroaddesign.com/catalog/doubler.htm

If sticking with the NP205 I personally would consider a double as the gearing in the 205 is not low enough. If going with a doubler using a NP203 GRB you may want to change the input of the NP205 to get as short as possible (ie 32 spline short female input requiring new input gear and boring the case for larger bearing)

 

[woody]

Honestly, the LT1 is nice, the TH350 is adequate, but the 205 case is a phat hog....and if you tack on a 203 in front of it, you've only made it phatter....

IMO, consider a t-case swap...either an Atlas or a D300, either will garner you 4:1 or better gearsets, and a lighter but more than adequately strong case.

FJ40 axles might hold up to the LT1, but yer gonna drop a minimum of $2k into the front to get it to last....since you have the D60 in there, stick with it.

 

[warpdriv]

Advanced adapter has a smaller driveshaft head (if thats what you call it) to it will not hit the tranny pan. That's the quick and cheap way.

HTH.

 

[HI^C]

np205 is very very little bigger the a stock cruiser case, within a inch of every measurement and only about 1.5" longer front to back. Where you can fit a cruiser case the 205 will fit and be better.


narrowed and offset Dana 60 front axle housing with 3rd member (Minus axle shafts). The front housing has also been retrofitted with Toyota knuckles and front disc brakes.

What the heck is this? sounds like this is a shot in the foot doing this one.

with a stock th350 to 205 adapter, unless you run a hp front housing or flat bottomed the frame rails with drivetrain install there is really no way you could have driveshaft clearence problems?
TAKE off the deep pan if you run one. Factory the front is already clocked about 2" down clocking it more just makes it a easier anchor.
OR is the driveline set too low in the frame rails? this is probably the problem.

smaller tube driveshaft?
none cv driveshaft?

Is the front pinion offest from the front ouput of the t case ALOT? this is the only other thing i could possible think of that could cause problems.

Auto will help with gearing, but the doubler would be nice but the whole driveline might need to be reset to take into account the add length. Also depends whats its main use is?