Best year for transfer cases??

[Civil1]

I am doing a 5 speed swap and would like to buy another transfer case so that I can get it all rebuilt and ready to install to minimize truck down time.

My question would be, what are the best years to buy?
Are there any years to avoid?

I know that sometime 85-86 or so they started using a larger 38mm idler shaft, does that mean I should avoid the ones with the 34mm idler shaft or is that even an issue.

I've got a lead on an 1983 for $300, I might be able to get it for $250.
What do you guys think?

 

[Cruiserdrew]

Use the one you already have.

You could use a 4/86-87 if you want the larger idler, but I don't think it makes much difference. Just make sure you get the right rebuild kit.

 

[Civil1]

Like you , when you did your 5 speed swap, I want everything ready to go the day I start the swap. So I found a used one off a 83 rig and did not know what difference their may be. I know that they will all work but sometimes their may be manufacturing differences between the years. You know mayby one year the used inferior materials than another year.

Just a thought, appreciate your reply.

 

[Cruiserdrew]

Like you , when you did your 5 speed swap, I want everything ready to go the day I start the swap. So I found a used one off a 83 rig and did not know what difference their may be. I know that they will all work but sometimes their may be manufacturing differences between the years. You know mayby one year the used inferior materials than another year.

Just a thought, appreciate your reply.

There is this lingering question as to whether the 82-83 cases have the rear input bearing area machined in the rear plate of the t-case that you need for this swap. For sure, the 84 cases have it. I *think* the 83s have it too, but I would have to open the rear cover to check. If it's there, then the 83 case would work fine. The $250 price is fair as well.

You are right about my swap. I kept the truck up and running until the day that all the new parts went in. That took all the pressure off finishing it and was well worth what I paid for my 87 case ($250 with shifter). You must get the later shifter(85-87) for the t-case. I assume you know that if you are in this deep. Post up if other questions. Mine's been in for almost a year and I'm extremely happy with the 5 speed. It's made me think about getting another H55 for my FJ40.

 

[Civil1]

Are you talking about the rear output bearing of the 5 speed transmission to the front of the transfer case. As in this picture.

Just so I know what to look for when I check out the 83 case.



Thanks for the picture

 

[Cruiserdrew]

Hey-that's a good picture. I'm actually talking about the bearing in the rear of the case. You can see it in this picture. The bearing is in place though, but the bore needs to be machined for this bearing for the t-case to work. If there was a local '83, I could tell in 5 minutes! This is the best pic that I have...

 

[lcwizard]

there are also gear ratio variations. i look for the years with the lower gear set. i believe it was 2.23 :1. When the fj60 ran 3:70 's in the axle the trans case had a lower set. whem the later 60' s went back to 4:11's the tranfer went to a 1.99:1

 

[Cruiserdrew]

there are also gear ratio variations. i look for the years with the lower gear set. i believe it was 2.23 :1. When the fj60 ran 3:70 's in the axle the trans case had a lower set. whem the later 60' s went back to 4:11's the tranfer went to a 1.99:1

Also a subject of much debate. The 60s (in the USA) NEVER had 4.11. They all had 3.70 diffs. The later 38mm t-cases for sure had 2.23:1 low range ratio. I thought the earlier cases had 1.99:1 low range, but FJ40Jim says that all the USA FJ60 split transfer cases had the lower ratio. Cruiserdan has confirmed this (sort-of) in that all of the gear sets have the same part # in Toyota's system.

The FJ62s did go back to 4.11 in the differentials, but retained the lower gear set in the transfer case.

 

[Civil1]

there are also gear ratio variations. i look for the years with the lower gear set. i believe it was 2.23 :1. When the fj60 ran 3:70 's in the axle the trans case had a lower set. whem the later 60' s went back to 4:11's the tranfer went to a 1.99:1

Good information, thanks

That brings me to another question.

Are the 62 transfer cases the same as the 60's?

Cruiserdrew, will I be able to tell if the bearing is machined by pulling off the tranny ouput shaft cover.

 

[Cruiserdrew]

Good information, thanks

That brings me to another question.

Are the 62 transfer cases the same as the 60's?

Cruiserdrew, will I be able to tell if the bearing is machined by pulling off the tranny ouput shaft cover.

The 62 cases are very similar, but they differ in some important respects. The case is vacuum activated, and the shifting shafts lack the detents. You can buy the internal parts from a 60 case and make the conversion-I believe beanzz2 has done it.

If you pull off the rear cover and see a bearing inside like the one in my picture above, then it has the correct machined bore. Please let me know what you find as I have been curious to know myself. I have an 84 case on my work bench and it has the machined bore. I think and hope the earlier cases have it as well.

 

[DaveWest5150]

I have converted one too I believe that they are all machined. and the only thing I had to do was drill out where the 2/4 wheel drive detent then thread it and install the detent itself. Depending on the install you may need to obtain a
different high /low arm as they are indexed, the vac. swings for and aft as where the manual swings side to side.
hope this helps.

 

[Civil1]

I don't think that I will be up for converting a 62 case, but its good information to have.

Andrew, I will let you know as soon as I find out about the 83 case.
I've emailed the guy but have not heard from him yet.

Thanks all

 

[Civil1]

Another thing to consider, for me anyway, would be the oiling cup for the 5 speed.

Do all the transfer cases have the provision for the oiling cup?

Just so everyone knows, I have never split a transfer case. This will be a learning experience for me.

 

[rick_d]

https://forum.ih8mud.com/showthread.php?t=94964

t-case conversion parts.

early 1981, 1982, and SOME 1983 models do not have machining for bearing shown by civil 1, this also includes the quarter size oil cup deal. John Hartman of Tucson has made an early case work with a H55, but not without some issues.

fj62's and all H55 factory applications I have seen, torn down, and measured have been 1.99:1 gear sets. All ENS canadian mine trucks with H55's got 1.99 gears til 1999.

Variations from 2.24-2.27 (I am sure 2.27 for 38mm FJ60 cases) for all US mounted H42 4speed applications.

34mm cases w/ 2.2+ gear sets run a 34 tooth input gear from tranny.
these gut can fit any 34mm case like H55 donors.

to sum, the 38 mm case delivered out of USA 10/85 and given to US FJ60's in 4/86 had the longest run of any t-case 10/85-5/1999. ENS reported 34mm gear sets could be pushed to the side, which never occured with 38mm cases.

38mm is the single best case if you can find one. Also, both 1/2's of the case ARE machined bolted together and Mudrak has reported problems with mixing and matching.

 

[lcwizard]

that's strange , iwent thru a case a few monthes ago with the higher set

 

[Civil1]

Thanks rick, good read. I don't spend much time in the diesel section.

Doesn't really appear that hard to convert a vacuum case to a manual. Unless I'm not geting the full picture. I'll look further into it.

 

[rick_d]

ok, let us look at just the low range gear 36204

sources are 1981-1987 non US J60 parts book, 1984-1990 non US J70 parts book, 1990-2004 J70 parts book, 1981-1984 NA J40/2 parts fiche, J60 NA parts fiche, J62 NA parts fiche.

US models FJ40, and FJ60 use the 60041 (43 tooth I think, I counted one 3 weeks ago in Nor Cal) for 34 mm idler
and the 60070 for 38 mm idler, April 1986 and later.

ATM's, FJ62 US, use the 60120, (which is 38 tooth and roller bearings)

CDN BJ42's and BJ60's WITH 4sp use 60041

CDN BJ42's and BJ60 with H55 use 60031 (unknown tooth, but creates a 1.99:1 output)

CDN HJ60' w/ manual use 60080 (which is 38 tooth, bronze bushed), 60120 atm (which is 38 tooth and roller bearings)

The world RJ/LJ, the HZJ71, J78 & J79 (post 1998 models) use the 60070, this in a R15X transmission

10/85 -9/99 world 5 speed (H55) manuals use 60080 (which is 38 tooth, bronze bushed, I've had 5 sets of these new and used from ENS)

We can see that for the better drive, the 60070 38mm low range gear or the 60041 34mm low range (43 tooth) are going to produce a 2.2+ gear ratio (2.27 is what I calc'd from a 1987 FJ60 donor)

 

[Cruiserdrew]

See this thread in "For Sale". He wants $175 for an 84 case. That's a great deal. I have bought a bunch of parts from him and have nothing but good things to say. He lives in the rust zone, so the steel parts like fasteners may have some surface rust. No affiliation, just a happy customer.

https://forum.ih8mud.com/showthread.php?t=95114

 

[Civil1]

Rick, thanks for the information

Andrew, thanks for the link.
I sent him an email; waiting to here from him.

 

[Civil1]

I got my used transfer case several weeks ago but have not had time to do anything with it. Well last night I started to disassemble in preparation to have it hot tanked and then rebuild. I must say thay due to work, I've really had no time to even look at the transfer case. We'll after working on it for a little while I started to think about the things that I needed for the case to work with my H55, you know the oiler cup and plugging the hole that is no longer needed. Well take a good look at this picture and you can see that the case has the provisions for the oiler cup, but no hole to be plugged.

When I bought the case I was told that it was an '84 but something tells me that it is not. Could someone inform me as to what I've got. What cruisers came with a transfer case mating surfaces like this?