Cutoff for transfer case needing mods for h55F swap

[edstorm]

Ive heard that the cutoff for fj60 models made after 06/85 as when the transfercase would need to be modded to fit the h55f. I have a transfercase from 08/85 and curious if it would fit in a fj60 from 06/86.

Thanks!

 

[cps432]

Ive heard that the cutoff for fj60 models made after 06/85 as when the transfercase would need to be modded to fit the h55f. I have a transfercase from 08/85 and curious if it would fit in a fj60 from 06/86.

Thanks!

I think it’s a difference in idler shaft diameter as well as number of splines. Older model has an 84mm shaft and the newer ones have 87mm I think. I haven’t dug into mine yet. I’ve read everything about them but I haven’t committed to the pain yet. I’m sure others will chime in and correct me if I’m wrong but I don’t think it’ll just bolt up. I do believe you need the later model tcase for the 5 speed.

Edit: Just reread your post. I kinda misunderstood you and though you had an early tcase. Measure your idler shaft. If it’s the larger one it should work.

 

[mattressking]

@orangefj45 put together some great tech, all you need to know. For you, just need to plug the 5th bolt hole above 5th gear oiler cup for splitcase to trans mounting and install 5th gear oiler cup. All covered below.

some h55f and split case tech

forum.ih8mud.com

 

[John Staton]

Mine is an '83 so wasnt a straight swap. I just purchased the H55 and a core transfer case and had it rebuilt and he sent them to me all together so I didnt have to worry about anything being done wrong. Sold the 4 speed and old transfer case after the swap. I used George Esterer at Valley Hybrids.

 

[edstorm]

Would love to rebuild the transfer case but I heard it’s around 1.8k to rebuild one now if it’s bad.

 

[Infinity00]

Why would it be $1800? Get the kit from Kurt @cruiseroutfit and rebuild it for less than $500. I don’t remember the exact cost for the kit but I do remember being pleasantly surprised at how inexpensive it was. I think less than $300 but I could be wrong.

 

[edstorm]

I think if the gears are messed up it could be the case. I’m not sure if the the rebuild kits take that into account.

 

[Infinity00]

Right, no it doesn’t, but if the gears are messed up I’d just buy a cheap used case and go from there

 

[mattressking]

Would love to rebuild the transfer case but I heard it’s around 1.8k to rebuild one now if it’s bad.

A new case sans a few pieces is $1800ish from Toyota.

Rebuild can be done for under 300 in parts of everything you have

 

[edstorm]

How do I tell how bad a transfer case is? Bring it to a pro?

 

[Prairie Swamp]

Take it apart and post up some pics if you're not sure.

 

[edstorm]

Will do.

 

[mattressking]

Will do.

If it goes into all hi/lot for 2wd/4wd smooth, just a rebuild kit should be it. If it has issues going into gear then you have to open it to inspect. There isn’t much to a transfer case, just a few gears, bearings/spacers/shims and gaskets. Don’t over think it.

 

[cruiseroutfit]

Why would it be $1800? Get the kit from Kurt @cruiseroutfit and rebuild it for less than $500. I don’t remember the exact cost for the kit but I do remember being pleasantly surprised at how inexpensive it was. I think less than $300 but I could be wrong.

Complete t-case rebuild kits are $245 (bearings, seals, gaskets, idler shaft, etc) and we offer BRAND NEW COMPLETE transfer cases for $1650, so yeah... $1800 is way over priced for rebuilding a t-case.

You can read more about them here on Mud:

YWST: Complete Split T-Cases - NEW

Yeah, We Stock That. Often customers just want a brand new OE T-Case and all the new parts to install it behind their existing transmission or one of our OE 5 speed H55F transmission options. Transmissions, transfer cases, flanges, gears, bearings, deals and more. We've got it ready to go. We...

forum.ih8mud.com

Pricing on our H55F's, t-cases, etc are on our website here:

Cruiser Outfitters

As far as which cases work for an H55F, really anything with an oiler provision will work. So that is ~10/1982 and later. The extra hole is a few dollars to resolve as needed. You can read more about the many different split-case variants here:

Cruiser Outfitters

 

[4Cruisers]

Older model has an 84mm shaft and the newer ones have 87mm I thnk.

34mm went to 38mm.

 

[cps432]

34mm went to 38mm.

I’m getting to young

 

[edstorm]

Here are pictures of a donor transfer case from a 86k mile FJ60. Worth pulling out and swapping into mine? Or is it a goner

 

[cruiseroutfit]

She looks rough but I'm sure it's workable

 

[OSS]

The transfer case is made of cast aluminum. Believe it it not, under that cooked on cruddy looking thing is a beautiful shiny aluminum case. All it takes is some elbow grease & polish

 

[orangefj45]

Here are pictures of a donor transfer case from a 86k mile FJ60. Worth pulling out and swapping into mine? Or is it a goner

View attachment 2009957

A case with less than 100k miles on it should be well worth rebuilding. We put together a "how-to" video a couple of years ago and can certainly help with parts and info. I've personally built a couple hundred of these cases.

Georg