Build Bj60 Barn truck rebirth + 13bt

[BryanLiew]

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.

 

[BryanLiew]

Cutting the output shaft!

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

 

[BryanLiew]

Got the ToyBox installed.

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.

 

[BryanLiew]

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.

 

[BryanLiew]

Got the toybox installed. 201:1 is going to be so helpful in the 60!
I still need to pick up a mini truck transfercase mount then build a skid plate/ crossmember for the toybox.

 

[woytovich]

I had a 4.7 toy box with a 2F, h55 and 4.56 gears in the diffs in my 60.... Stupid slow, stupid fun!

 

[BryanLiew]

I had a 4.7 toy box with a 2F, h55 and 4.56 gears in the diffs in my 60.... Stupid slow, stupid fun!

good to know, I also have 4.56! Did you do any highway driving? I'm wondering if you ever had any problems with the toybox?

 

[woytovich]

By the time my 60 got to that point I really wasn't driving it on the street very much. I had 38-in swampers on it with bead locks and it wasn't really a road trip truck any longer.