FAQ Guide - Converting A440F automatic to H55F manual (1 Viewer)

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ATL Cruiser

ATL Cruiser

GOLD Star
Joined
Aug 1, 2022
Threads
51
Messages
652
Location
Atlanta, GA
My HZJ77 left me stranded a few months ago. The A440F automatic transmission blew up internally with zero line pressure.

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I always felt that the automatic transmission robbed a lot of power. I mean, the thing is absolutely massive:

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Instead of rebuilding the automatic unit, I decided to swap out for an H55F manual transmission. This turned out to be a major undertaking sourcing parts from around the world:

  • H55F transmission + transfer case
  • Crossmember + gussets + mount
  • Driveshafts
  • Transfer lever
  • Wiring harness
  • Clutch pedal
  • Clutch hydraulics
  • Shift console
  • Carpet
  • Shift knobs
  • Shift lever
H55F TRANSMISSION + TRANSFER CASE
Grateful to @orangefj45 for sourcing the transmission and transfer case. Georg also installed a 10% higher final gear, which makes highway driving nicer. It all arrived in a mega crate in perfect condition. I ordered the correct bellhousing + both sets of dowels (trans side and engine side) and installed it.

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CROSSMEMBER + GUSSETS
Upon installing the transmission, I realized that there was nothing to bolt the rear trans mount to. Toyota built two versions of the HZJ77 frame. One with automatic, one with manual. The manual transmission crossmember sits about 12" further forward:

1686049851539.png


I ordered the correct gussets + crossmember + trans mount and welded them in place. I highly recommend getting a level gage to set the correct driveshaft pinion angle before welding everything in place.

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Klein 935DAGL is a great digital level tool for setting the pinion angle before welding in the gussets. If you have a lift on the rear, you will need to install leaf spring angle shims as well.

1686057991416.png


DRIVESHAFTS
The automatic and manual HZJ77's have different front and rear driveshaft lengths. Rough measurements:
  • Front driveshaft (automatic): 798mm (31 7/16")
  • Rear driveshaft (automatic): 968mm (38 1/8")
  • Front driveshaft (manual): 679mm (26 3/4")
  • Rear driveshaft (manual): 1108mm (43 5/8")
The front manual driveshaft is still available new. The rear, no. The HZJ77 is a "medium-long wheelbase" which is somewhat of an oddball. Instead, I found a used driveshaft on Yahoo Auctions Japan, ordered it, and got it all rebuilt here locally. Another option would be to bring the automatic driveshaft to a shop and have them resize it.

TRANSFER LEVER
Since the transmissions are different lengths, the transfer case lever needed to be shortened. @cruisermatt sells these for the 60 and 70 series. It worked fantastic.
1686051738041.png


WIRING HARNESS
The manual transmission and automatic also have different wiring harnesses. @cruisermatt also sells and adapter harness which he sent. It fit and worked perfectly. I forgot to take a picture of the harness, but it's plug-and-play.
 
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CLUTCH PEDAL
The clutch pedal turned into a mess. Toyota made 4 x 70 series clutch pedal assemblies (that I know of):

1686052193318.png


Only the middle clutch pedal fit. The HZJ77 came with a clutch booster assembly. This is likely why the standard 70 series pedal did not fit. I chose not to go the booster route, as the clutch pressure plate is not that strong (in my opinion), and it's fairly easy to press with no clutch booster.

1686052375777.png


CLUTCH HYDRAULICS
I ordered a new master + a couple versions of the slave cylinder. Both worked fine.
Slave cylinder: 7/8" bore (31470-60290)
Slave cylinder: 13/16" bore (31470-60161)

I found a clutch hydraulic line from an Australian junkyard. They shipped it over, and it fit perfectly. This part is obviously not necessary, but it saved me time with bending and flaring. Additionally, it looks OEM, instead of janky "custom" install.

1686060068477.png


1686060108131.png


SHIFT CONSOLE
The shift consoles are different between the automatic and manual. Neither are made any more. I actually found a few from a junkyard in Pakistan and had them sent over. Be careful, as there are two versions of the manual shift console. One for the H55F and one for the R151F:

1686053044771.png


1686053410478.png


CARPET
The dead pedal leave a big ugly carpetless hole in the floor. Thankfully @sleepydad69 sent me a hunk of carpet to make it look nice again. I didn't go full monty and replace the entire front carpet like he did. Baby steps here.

1686053190640.png


1686053204421.png


SHIFT KNOBS
The shift knob options have been covered in detail. Example from @bottombracket

forum.ih8mud.com

Builds - An HJ61 followed me home to Texas

If I had it, I would. @Onur can you help me?
forum.ih8mud.com forum.ih8mud.com

However that post is missing two knob options. Including possibly the hottest leather-clad knobs ever made - the 70th Anniversary knobs:

1686071941178.png


SHIFT LEVER
Toyota actually makes two shift levers for 70 series. One is for LHD and one for RHD. Unfortunately, I ordered the LHD without thinking, and I was reaching over to the passenger seat to shift. Make sure to order the correct shift lever, so it points towards the driver.

1686072131372.png
 
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MEGA PARTS LIST
1686053584049.png


PartPart NumberNotes
M/T radiator:16400-17080Toyota dealership
Rubber boot - shifter:58280-60060Online
Rubber boot - transfer shifter:58290-60060Online
Shift Rod (LHD version):33530-60160Online
Shift Rod (RHD version):33530-60210Online
Knob - shifter (70th anniversary):33504-20120-C0Online
Knob - transfer (70th anniversary):36303-60240-C0Online
Shift console plastic assembly:n/aUsed
Shift console metal plate:58207-60030Used
Shift console metal plate seal:58263-90K00Used
Carpet:58510-60690-03Used
Front driveshaft:37140-60280Online
Rear driveshaft:37110-60470Used
Transmission mount:12371-17010Online
Transmission crossmember:51202-60110Online
Crossmember bolts x 8:90119-10449Online
Crossmember Gusset x 2:51322-60080Toyota dealership
Crossmember Gusset x 2:51321-60090Toyota dealership
Brake pedal box assembly:n/aUsed
Clutch pedal box assembly:n/aUsed
Clutch pedal cushion:90541-06036Online
Clutch pedal pad:31321-14020Online
Clutch master cylinder (3 bolt w/ booster):31401-60060Online
Clutch master cylinder (3/4" bore) (2 bolt w/o booster):31410-60432Online
Clutch master gasket (3 bolt w/ booster):31415-60010Online
Clutch master gasket (2 bolt w/o booster):31415-60020Online
Clutch slave cylinder (7/8" bore):31470-60290Online
Clutch slave cylinder (13/16" bore):31470-60161Online
Clutch accumulator:31490-60051Online
Clutch booster:31440-60100Online
Clutch vac reservoir:31430-60080Used
Clutch slave hydraulic hose:96812-50260Online - made 50mm longer
Clutch hardline hydraulic tube:31481-60412Used
Clutch fork boot:31126-60070Online
Clutch fork ball:31236-35030Online
Clutch fork31204-36110Online
Input Pinion Bearing90363-15017Online
Flywheel (275mm):13405-17010Online
Clutch31250-60432Online
Pressure Plate31210-36330Online
Throwout Bearing31230-60130Online
Terrain Tamer Clutch Kit (275mm):TTCK6869HPOnline
Terrain Tamer Clutch (Exedy):TYD107YTFPart of kit
Terrain Tamer Pressure Plate (Exedy)TYC540TFPart of kit
Terrain Tamer Throwout Bearingn/aPart of kit
Terrain Tamer Pilot Bearing (NACHI)15BC04S18SSUPart of kit
Flywheel (300mm):13405-17020Online
Clutch31250-60401Online
Pressure Plate31210-60122Online
Throwout Bearing31230-60130Online
Transmission plate RH:33118-60060Online
Transmission plate LH:33119-60031Online
Housing cover LH:31121-26020Online
Housing cover RH:31121-60040Online
Bellhousing:31111-60230Online
Bellhousing Plate:11355-17011Online
Slave cylinder bolt (x2)91611-B0825Online
Flywheel bolts (x6)90105-12169Online
Flywheel dowel (x3)90250-10192Online
Pressure plate bolt (x6)90119-08134Online
Starter studs (x2)92136-61245Online
Bellhousing rear bolt (x4)91619-61245Online
Bellhousing front bolt (x9)91619-61245Online
Bellhousing rear dowel (x2)90250-12146Online
Bellhousing front dowel (x2)90250-08054Online
Stiffener bolt (x4)91619-61235Online
Crossmember bolt (x4)90119-10449Online
Trans mount bolt (x4)91629-B1225Online
Trans mount washer (x2)90201-12208Online
Trans mount nut (x2)90179-12090Online
Trans mount nut (x2)90179-12115Online
 
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ATL Cruiser said:
MEGA PARTS LIST
View attachment 3341906

PartPart NumberNotes
M/T radiator:16400-17080Toyota dealership
Rubber boot - shifter:58280-60060Online
Rubber boot - transfer shifter:58290-60060Online
Shift Rod (LHD version):33530-60160Online
Shift Rod (RHD version):33530-60210Online
Knob - shifter (70th anniversary):33504-20120-C0Online
Knob - transfer (70th anniversary):36303-60240-C0Online
Shift console plastic assembly:n/aUsed
Shift console metal plate:58207-60030Used
Shift console metal plate seal:58263-90K00Used
Carpet:58510-60690-03Used
Front driveshaft:37140-60280Online
Rear driveshaft:37110-60470Used
Transmission mount:12371-17010Online
Transmission crossmember:51202-60110Online
Crossmember bolts x 8:90119-10449Online
Crossmember Gusset x 2:51322-60080Toyota dealership
Crossmember Gusset x 2:51321-60090Toyota dealership
Brake pedal box assembly:n/aUsed
Clutch pedal box assembly:n/aUsed
Clutch pedal cushion:90541-06036Online
Clutch pedal pad:31321-14020Online
Clutch master cylinder (3 bolt w/ booster):31401-60060Online
Clutch master cylinder (3/4" bore) (2 bolt w/o booster):31410-60432Online
Clutch master gasket (3 bolt w/ booster):31415-60010Online
Clutch master gasket (2 bolt w/o booster):31415-60020Online
Clutch slave cylinder (7/8" bore):31470-60290Online
Clutch slave cylinder (13/16" bore):31470-60161Online
Clutch accumulator:31490-60051Online
Clutch booster:31440-60100Online
Clutch vac reservoir:31430-60080Used
Clutch slave hydraulic hose:96812-50260Online - made 50mm longer
Clutch hardline hydraulic tube:31481-60412Used
Clutch fork boot:31126-60070Online
Clutch fork ball:31236-35030Online
Clutch fork31204-36110Online
Input Pinion Bearing90363-15017Online
Flywheel (275mm):13405-17010Online
Clutch31250-60432Online
Pressure Plate31210-36330Online
Throwout Bearing31230-60130Online
Terrain Tamer Clutch Kit (275mm):TTCK6869HPOnline
Terrain Tamer Clutch (Exedy):TYD107YTFPart of kit
Terrain Tamer Pressure Plate (Exedy)TYC540TFPart of kit
Terrain Tamer Throwout Bearingn/aPart of kit
Terrain Tamer Pilot Bearing (NACHI)15BC04S18SSUPart of kit
Flywheel (300mm):13405-17020Online
Clutch31250-60401Online
Pressure Plate31210-60122Online
Throwout Bearing31230-60130Online
Transmission plate RH:33118-60060Online
Transmission plate LH:33119-60031Online
Housing cover LH:31121-26020Online
Housing cover RH:31121-60040Online
Bellhousing:31111-60230Online
Bellhousing Plate:11355-17011Online
Slave cylinder bolt (x2)91611-B0825Online
Flywheel bolts (x6)90105-12169Online
Flywheel dowel (x3)90250-10192Online
Pressure plate bolt (x6)90119-08134Online
Starter studs (x2)92136-61245Online
Bellhousing rear bolt (x4)91619-61245Online
Bellhousing front bolt (x9)91619-61245Online
Bellhousing rear dowel (x2)90250-12146Online
Bellhousing front dowel (x2)90250-08054Online
Stiffener bolt (x4)91619-61235Online
Crossmember bolt (x4)90119-10449Online
Trans mount bolt (x4)91629-B1225Online
Trans mount washer (x2)90201-12208Online
Trans mount nut (x2)90179-12090Online
Trans mount nut (x2)90179-12115Online
Click to expand...
Great detailed information here. What junkyard in Australia was willing to look for parts for you and send to you?
 
prwillard2 said:
Great detailed information here. What junkyard in Australia was willing to look for parts for you and send to you?
Click to expand...
I called so many that I don't even remember any more. There are at least 20 yards that I called and/or emailed. Here's a few to try, though:

https://www.cruiserutesandparts.com.au/
Early Landcruiser Spares & Repairs - https://earlylandcruiserspares.com.au/
Nova 4x4 - Top Quality Land Cruiser 4x4 Parts Perth Australia - https://www.nova4x4.net/
Used - https://www.4wheelauto.com/used/

@joekatana also had a few odds and ends on the shelf that I bought. Very grateful for his help as always.

For what it's worth, if you're thinking about doing this, it would be way easier to sell your rig and buy a manual setup. Just my two cents. @joekatana told me this, but I ignored him. 🤣
 
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Dude, do you ever sleep?

Exquisitely done.

Moderators, please make this a sticky.
 
amazing work! hope you get to enjoy the rig and its new transplant now that the entire swap is done!
 
Awesome write-up Wes. Glad I was able to help with the conversion parts! :cool:
 
Wow this is the first time I have ever seen a factory Automatic 70 series!!
Wonder why they were never avaliable here in Australia
I am about to start doing the reverse to you for both medical and pure love of Auto reasions
Sadly my days of driving a Manual have vanished due to a bung left foot!

I have just put up a post asking for information such as electrical plug pin outs and diagrams so anything you have would be appreciated and any suppliers willing to deal with me also appreciated as my budget is tight due to recent time off work due to my injury.
items such as tail shaft mods I can get done locally and not too expensive but any hints apreciated.
 
Troopiepete said:
as my budget is tight
Click to expand...

This is a massive undertaking. I own a large scale shop, and it still took me 2-3 months of simply sourcing parts for it and running into countless roadblocks. I would never do this again unless I had a salvage donor truck to cannibalize sitting in the bay right next to mine.

Additionally, I went from complex-to-simple. You are going from simple-to-complex. For example, the A440F requires an ECU for shifting (unless you find a pre 1992, fully-hydraulic A440F with no ECU. But this is tough, because everyone in Australia wants this version). Simply wiring this in is going to be difficult.

The automatic transmission crossmember is HZJ77 specific (or at least medium-long body specific), so they have not been produced for ages. You will need to fabricate the crossmember and/or find one.

The transmission rear rubber mount is NLA from Toyota. There is an aftermarket mount made for it, but those are tough to find as well. I think they only did one run of these mounts a few years ago.

The shift console will not exist, and you will need to find one in a junkyard, along with the shifter and all linkages.

The automatic radiator is no longer made. You will need to add an aftermarket transmission cooler to yours, along with all the plumbing.

Essentially, any non-wear item on this project will need to be sourced from a salvage yard somewhere. Toyota no longer produces the non-wear items. Thankfully, you are in Australia, and there would be plenty of 70-series in junkyards around there. However, anything firewall-back will be 77 specific.

With all that said, this is not a project I would take on without a substantial budget of money, time, and worldwide contacts for NLA parts.
 
Troopiepete said:
Wow this is the first time I have ever seen a factory Automatic 70 series!!
Wonder why they were never avaliable here in Australia
I am about to start doing the reverse to you for both medical and pure love of Auto reasions
Sadly my days of driving a Manual have vanished due to a bung left foot!

I have just put up a post asking for information such as electrical plug pin outs and diagrams so anything you have would be appreciated and any suppliers willing to deal with me also appreciated as my budget is tight due to recent time off work due to my injury.
items such as tail shaft mods I can get done locally and not too expensive but any hints apreciated.
Click to expand...
Do yourself a favor and just import a cruiser with a factory auto from Japan , still will be a s***ty transmission but at least you didn't put tons of time and money in to it , anything younger then 25 years should still be reasonably priced there .
 
Yep both valid points but I have the best motor and have every mod under the sun in this Troopy so while even selling it in the current state of remaining covid tax on vehicles like this I would never be able to replace it to the point I have it now..
 
Wagchio said:
hi @ATL Cruiser . Thanks for posting this great guide. Please, is it possible to have info on the taller gear from @orangefj45? Is it a replacement for the 5th gear?
Click to expand...
You are most welcome. Yes, it replaces the 5th gear. I do not know the part number nor details, however. Sorry. Georg may chime in if he sees this.
 
ATL Cruiser said:
You are most welcome. Yes, it replaces the 5th gear. I do not know the part number nor details, however. Sorry. Georg may chime in if he sees this.
Click to expand...
hi....
unfortunately, no news from @orangefj45 yet... checking on Cruiser Brothers, I see this set, but it does not seem compatible with H55F transmissions
cruiserbrothers.com

33428-HZJMOD Gear Set, 5th Gear Modified Ratio, .711 from .838 - CruiserBrothers

Gear Set, 5th Gear Modified Ratio, .711 from .838
cruiserbrothers.com cruiserbrothers.com

possibly these fit: Sumo Gear 10% Overdrive High Range Gears - Fits 1986 & Newer 38mm Split T-Case - https://cruiserteq.com/sumo-gear-10-overdrive-high-range-gears-fits-1986-newer-38mm-split-t-case/

www.terraintamer.com

HIGH GEARED RATIO KIT TRANSFER CASE 0.909-1.904 10/28% INCRE

HIGH GEARED RATIO KIT TRANSFER CASE 0.909-1.904 10/28% INCRE
www.terraintamer.com www.terraintamer.com
 
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