I started the Marlin Crawler ToyBox install. I’ve seen some people have issues with the H55F output shaft retention where the shaft collar can shift over time.
To address that, I had a new split shaft collar made with mechanical engagement into the groove on the H55F output shaft instead of relying only on clamp force. The groove engagement is a backup incase the clamp force/friction fails. I also shortened the spacer slightly on the lathe to make room for the larger collar.
To determine the cut location, I measured the depth of the splines in the ToyBox input gear and left a small gap between the end of the splines and the bottom of the pocket for clearance.
I then transferred that measurement onto the H55F output shaft and marked the cut line. To keep the cut square and avoid damaging parts, I used the original shaft collar with a washer behind it as a guide while cutting the shaft with a grinder.
I also re-measured the shaft length and the input gear depth to ensure the h55f shaft doesn’t bottom out in the gear.
I finished off by putting a small chamfer on the end of the splines
Ran into two issues during install. The input wouldn’t fully seat at first, so I lightly sanded the H55F splines for fitment. From the research I did before starting, this seems to be a common thing.
I was also missing two dowel pins between the ToyBox and split case. I ended up making a set rather than waiting days for replacements in the mail. I measured some dowels from a disassembled h55F.
I got my injectors back from being refreshed. While I was installing them and working on the 60’s interiors. My brother shortened the rear driveshaft and set it up for welding.
