Fj60 five speed swap *HELP* (1 Viewer)

[Rider977]

I’m in the process of putting in a new h55f transmission into my ‘87 fj60. I got the old tranny/transfer case out, installed new oil pan, new real main seal and swapped the transfer case onto the new transmission after a lot of cleaning. I am not mechanically inclined, but with the help of this forum and YouTube videos I was able to slowly work through doing this alone. Was almost done re-installing it and ran into an issue:

When putting on the new shifter, the little plastic bushing came off the bottom that goes into the transmission—and it fell into the bottom of the transmission housing. I thought I might be able to take off the top cover and fish out while still inside the cab. Couldnt remove the top cover fully because of issues with the dash and the 5th gear arm just barely catching on the hole in the base board. While wiggling the top cover around I heard a couple small metal pieces fall into the transmissible hosing as well. At this point I had to take the whole transmission back out—as I did not know what fell into the bottom of it.

Once back out I found that a ball bearing and a small metal pin had fallen out from under the top cover. I was able to fish them out with a long magnet. I found where the bearing came, from but I can’t figure out where this little tic-tac sized pin came from. I put everything back together including the shifter—accept the little pin—and it seems to function normally as far as shifting through the gears. Any help in identifying this piece and where it belongs would be greatly appreciated.

 

[RevISK]

Is it one of the pins the shifter locks on up top?
Hard to see how those would pop out but who knows?

Maybe post a shot of the top side for kicks.

 

[Rider977]

it’s a bit smaller and brighter than the pins that hold the shifter in place.

 

[RevISK]

Worth a shot.
That sucks man. If I were you I’d be finding the service manual for the H55f and combing through that.

Just doesn’t seem like that stuff should be falling out.

Did you get the tranny from Georg?
He’d certainly know where the came from.

 

[RevISK]

Worth a shot.
That sucks man. If I were you I’d be finding the service manual for the H55f and combing through that.

Just doesn’t seem like that stuff should be falling out.

Did you get the tranny from Georg?
He’d certainly know where the came from.

Couldn't stand it. Found a copy of the manual. I think it is an "Interlock Roller or Pin"

 

[Rider977]

Yes it looks like it’s the interlock roller based on the diagram. Put it back where it belongs as far as I can tell based on the diagram. It’s a little vague on exact location but I think it’s in the right spot. I re-assembled everything on the transmission stand before I’m gonna try and put it back into the rig tomorrow. Everything seems to work like it’s supposed to.

Thank you for your help I really appreciate it.

 

[RevISK]

Yes it looks like it’s the interlock roller based on the diagram. Put it back where it belongs as far as I can tell based on the diagram. It’s a little vague on exact location but I think it’s in the right spot. I re-assembled everything on the transmission stand before I’m gonna try and put it back into the rig tomorrow. Everything seems to work like it’s supposed to.

Thank you for your help I really appreciate it.

You’re welcome Rider. If you poke around you’ll see I’ve had quite the run with transmissions.
Also, that’s what this site is all about.

 

[Eurasiaoverland]

I fully rebuilt my H55F including a new cover, so I have completely dismantled and reassembled the shifting assemblies.

I don't see how that interlock pin could come out, it should never be in a position to fall out within the normal range of the shifting shafts. The interlock rollers and pins are there to stop you double-locking the gearbox, i.e. putting it in two gear ranges at once, which would have catastrophic consequences. The ball bearing is a spring-loaded detent, which keeps the shift-shaft in the correct position and gives you that feeling of positive gear engagement.

You can't just go poking those pieces in somewhere where they might fit. The only way now to be sure that it is built properly is to strp it backk and rebuild it correctly.

You can see one of the two interlock pins (which are thinner than the interlock roller on the 4-speed diagram posted above) here on the 3rd/4th shift fork and shaft sub-assembly.

One thing I would check is you E clips - these limit the movement of the shafts. There should be three E clips on various shifting shafts, and one plain, open spring clip:

It's not hard to rebuild the whole cover assembly, but you'll need to read and understand the correct H55F (not the 4 speed) factory service manual. You'll need some pin punches and locking compound like blue/green Loctite. If you bought it from a reputable source, you could approach them and ask for their help.

 

[RevISK]

My mistake for not posting the correct page. I'll post the one to the 5 sp below. I agree with @Eurasiaoverland that things shouldn't just be falling out. Something else is afoot with your tranny.

 

[Rider977]

Thanks for your input.

I didn’t clarify, but I had found the online file with the correct 5 speed specific page and went off that for replacing the interlock roller. It definitely was not the interlock pin that is in your photo. The e-clips are all in the correct place and function as they should. Everything seems to function normally now.

 

[Eurasiaoverland]

Oops, my bad. If you've built it back using the manual and it shifts normally, and you can turn the gearbox in every gear, then it should be good to go, but I'd be wary of why it fell out. Did you get the shift heads in the wrong order and somehow move a shaft too far?

 

[Rider977]

Yes I’m pretty sure that’s what happened. Trying to wiggle the top cover off with the tranny installed was a bad idea. I think I moved the 5th gear shaft too far and it and cause the interlock roller and bearing to come out. I really didn’t want to drop the tranny back out after re-installing it so I was wiggling it and twisting it more than I should have.

The shift heads were initially out of place but I used this forum to sort that out.

Like I said, everything seems to function normally. It shifts through the gears smoothly and the gearbox turns in every gear. Transfer case functions normally as well.

 

[Rider977]

I reinstalled the transmission today and took it for a test drive. Everything shifts smoothly and reverse works fine as well. Thanks again for your guy’s help.

 

[Eurasiaoverland]

I reinstalled the transmission today and took it for a test drive. Everything shifts smoothly and reverse works fine as well. Thanks again for your guy’s help.

Happy 5-speeding!

 

[RevISK]

I reinstalled the transmission today and took it for a test drive. Everything shifts smoothly and reverse works fine as well. Thanks again for your guy’s help.

Amazing.