Another Auto to Manual Switch. Question about driveshafts and such.

[Saucerman]

The A440 is coming out this Winter and probably a 4 speed going in. I have read the previous swap threads but found nothing definitive about new drive-shaft lengths. It seems you an use your existing FJ62 shafts if they are cut and re-welded but it seems they are not a uniform size in every truck that has done the changeover. Is this correct?
Also I have a choice from a vendor to order an H42 long or short style. I have no idea what this means. Will it matter for my conversion?
And...do manual transmissions also need the coolers like the A440's?

 

[georgebj60]

Calling @Paul DiNapoli ! I can't answer all your questions, but I can offer a little bit of info.

The long style vs short style H42 refers to whether it's an early 60's transmission that does not have a fifth gear spacer (short), or the later style that does (long). For people swapping an H55F into a 60, the later trucks with the longer H42's are preferred as you can re-use your existing driveshafts.

I think in your case however, you'll need to have your driveshafts modified to suit. And if you have a lift that would change things too. Others with more experience with me should be able to offer more clarify on this point.

And no, manual transmissions do not use an oil cooler. They are full of gear oil, similar to a differential, and it does not get circulated by a pump, it just splashes around.

 

[Paul DiNapoli]

I was confused by all this when I did my swap too...maybe these visuals will help.

first - the a440 + t-case is like a mile long...so the distance between the 2 flanges is distance X

the H42 & H55 are much shorter gearboxes - so once the gearbox is assembled with the t-case attached and bolted up to the bell housing at the back of the block - the distance between those 2 flanges ends up greater after the swap since everything shifted forward by X.

Hence the rear drive line out of your rig is no longer able to reach. a drive line shop will make you a new one by retubing it...or you find one out of an FJ60 and you reuse it.

Since everything shifted forward by X - the old drive shaft that you pulled off the front of your truck is now too long...so it needs to be shorter. this one is a little easier in that a shop can just cut it - reweld it and balance it.

the rear needs to be longer so I think they reuse your flange hardware and simply retube it...so there's some material cost involved.



hopefully this clears up the difference between H41 / H55:

H42 without the 5th gear spacer block shown here with the t-case bolted right to the back of the 4 speed gear box.

later H42 with 5th gear spacer. still might have been a 4 speed gear box - but with this spacer. (someone else correct me here if i'm wrong...i have no idea why they'd make a 4speed with the 5th gear spacer attached - but still build it as a 4 speed??)

but at any rate... some of the later year H42's had this 5th gear spacer block.

a few things dictate the next bit of info/advice if you're doing your own swap
do you have access to a lift - or is the truck jacked up on jack stands?

regardless - the point is...once you have your new gearbox bolted in and secured...assuming the truck is sitting on jack stands at all 4 corners...the suspension is totally relaxed so your axles are at their lowest point.

take flange to flange measurements for front and back while in this relaxed position.

then - put your wheels on (assuming the wheels are off for the project) drop the truck down on the ground to put weight on the springs and compress the suspension...then take another set of flange to flange measurements front and back.

write down both and give them to your drive line shop when you ask them to make you new ones.

both the drive shafts have a slip yoke like this:

that gives the drive line the ability to compensate for suspension travel front to back.
if the drive line shop makes them too long and there's not enough room for travel - then under certain conditions they could bottom out and stuff could break badly.


these were my measurements:
flange to flange distance with truck sitting on jack stands and the suspension relaxed
42.5" rear
26 3/8" front.

flange to flange distance with wheels on - truck sitting level and suspension loaded
42.5" rear
26 3/4" front.
(i'm a little surprised/confused by the fact that my rear measurement didnt change. i didnt trust it so i did it twice...

don't assume my measurements will work for you...get your transmission & transfer case bolted in then take measurements. or if you're lucky you have drive shafts out of an FJ60 with 5 speed spacer - and they just bolt right in.


i'm in portland - a shop made these for me.

paul dinapoli - H55 swap thread

Black O2 wires are the heater power - non-denominational. Thanks for documenting this. Mine will happen this fall.

forum.ih8mud.com

 

[Saucerman]

Nice! Thanks for the responses and pictures. Paul your thread was one of the ones I studied before deciding to make the switch.
I am doing the job in my own driveway. It sucks but that is all the space I have. I have all manner of jack-stands and hydraulic jacks and even a transmission jack. It will probably take me all winter to complete but that’s okay.
I first have to rebuild the transfer case coming with the 4 speed. It seems that is what everyone does as ii is easier when it is off the truck.

 

[Saucerman]

You know what? Can I re-use my transfer case from my A440F if I rebuild it?

 

[Paul DiNapoli]

You know what? Can I re-use my transfer case from my A440F if I rebuild it?

you sure can. that’s what i did.

 

[Saucerman]

Yeah, I saw you did but you used an H55. I am going with the H42. It would be awesome if I could though then I could go ahead and take that out and start with the rebuild. Valley Hybrids has rebuild kits that have bearings, seals and everything.

 

[Paul DiNapoli]

Yeah, I saw you did but you used an H55. I am going with the H42. It would be awesome if I could though then I could go ahead and take that out and start with the rebuild. Valley Hybrids has rebuild kits that have bearings, seals and everything.

yeah - you have a lot of options. the H42 vs H55 part has little bearing on t-case sourcing part of the project. Either find a used one and rebuild that while you drive your rig...or tear yours down and reuse the one you have. using the one you already have is nice if you know the history and then you don't have an extra one laying around after the project that you want/need to get rid of
(unless you like hoarding parts and an extra t-case is desirable?)

i daily driver my 62 -so this was my situation:

I wasn't up for rebuilding my t-case...there's a few tools required that I was not interested in acquiring for 1 time use...so I had my new H55 delivered from Toyota to my local cruiser specialist shop. My local cruiser shop had a used transfer case sitting in storage so I paid him the labor to rebuild that t-case with the promise that he gets mine as swap for the one he "gave" me. It was a bit of a favor to me - but I've spent a lot of money with him and he trusted me to do the right thing...the t-case out of my rig was to replace his inventory.

This allowed him to rebuild the used t-case in his shop and mate it to my new gear box and hand it over to me as "ready to install kit" .

I paid him the labor for this work and took home the assembled gearbox/t-case kit so i could do the rest of my swap on my own.

This kept me rolling in my own truck while I was still acquiring all the other swap parts I still needed.

everyone's situation plays out a little different for various circumstances / money / time / skills / space / spouse tolerance for ongoing project - etc...

i am curious - why the 4 speed? is there a reason you don't want the 5th gear, or perhaps you already have the H42 - or don't have the funds for a new H55?

 

[Saucerman]

My situation is similar. I don't daily drive the 62 but would like to use it more.
Currently the auto trans is acting up pretty bad making it usable only for short trips.
As far as the H42 choice. I live in a crap traffic area. Live 14 miles from work and takes an hour plus to get here. Really fun. I do use it to get me way out to do my hiking trips. Overdrive would come in handy for that but oh well. I just can't afford the H55 right now. The 4 speed would be pretty nice and would be less hassle for the future. I really liked the auto but again, the price was prohibitive. I come from the old air-cooled VW world so I have wrenched on things for years. That is not to intimate skill, just familiarity.

 

[Paul DiNapoli]

My situation is similar. I don't daily drive the 62 but would like to use it more.
Currently the auto trans is acting up pretty bad making it usable only for short trips.
As far as the H42 choice. I live in a crap traffic area. Live 14 miles from work and takes an hour plus to get here. Really fun. I do use it to get me way out to do my hiking trips. Overdrive would come in handy for that but oh well. I just can't afford the H55 right now. The 4 speed would be pretty nice and would be less hassle for the future. I really liked the auto but again, the price was prohibitive. I come from the old air-cooled VW world so I have wrenched on things for years. That is not to intimate skill, just familiarity.

old school VW!! cool - I've owned a few type3 fastbacks, and restored a 69 Squareback that I drove her for about 15 years. kinda miss her.

 

[Saucerman]

You are right they were cool and I miss them too. Talk about skyrocketing prices too!
These trucks are fun too though and I always wanted an FJ62, since seeing my girlfriend's dad's truck back in high-school.