H55 FJ55 Pig Transfer Case Info

[Cruiserdrew]

why is this critical? and by shift linkage you mean just the shifter and associated rods / retainer on the transfer case?

Noah

It's critical because the shift linkage from 84 and down is too short to shift the 4WD shifter rail, since it's built to use on the shorter tranny. Remember, the 85 up H42 tranny got an extension housing to make it the same length as the H55, so those shifters work.

It's also necessary to make a cross member to hold the tranny, since the 81 and up H42s mount differently. I saw a slick set up that Mudrak did, where he took the cross member out of an 81 FJ40, and used that to support an H55f in a 69 FJ40. It looked factory. You will also need that rear motor mount if you go that route so add $125 to your planning.

And one other thing. If you need the e-brake, then MAF may be your only option. If you don't, the flanges from all years of the split case will interchange. Up untill 84 the flange bolt pattern is correct for 75 and later FJ40s (and possibly earlier-measure). To make mine work, I used 83 flanges to match up to my existing 84 bolt pattern, so I could retain the same driveshaft pattern. The alternative is to swap new flanges on your differentials.

 

[PabloCruise]

This is turning into a good thread...

 

[PabloCruise]

Flanges by year:

Courtesy of Toyota Trails (TLCA) and Kurt @ Cruiser Outfitters.

 

[FJ40Jim]

There is one error in the above diagram. The change to fine spline pinion happened in 1/78. This according to the parts fiche, as well as empirical evidence.

 

[PabloCruise]

There is one error in the above diagram. The change to fine spline pinion happened in 1/78. This according to the parts fiche, as well as empirical evidence.

That would make sense...

 

[cruiseroutfit]

Wish I could find the link, but I posted a pile of H55f swap pics from my truck and a couple of other local swaps... I used a shortened FJ60 crossmember in mine... super beefy and no problems in 5 years.

There is no reason you can't use a 34mm case assuming it has the oiler provisions as Cruiserdrew pointed out. I think we've had this conversation many times in the past but the best we came up with is pretty much what Cruiserdrew stated... most of 83' and everything after. In fact I run an 84' split-case in my FJ40 behind the H55F. I had the choice of a dozen or so cases, I didn't really look for the 34/38mm difference, rather which one was the cleanest. The 38mm's that originally came behind a rig with a spacer (Cdan's computer indicated 4/85' as the cuttoff) will need to tap and plug a hole in the t-case (where a bolt used to attach to the middle of the spacer). I know of a few situations where are guy had a a later model (7/85') with the spacer... but it was a 34mm case (https://forum.ih8mud.com/showthread.php?t=30799&page=3&highlight=h55f)

Also some other considerations...
The mods needed on the bellhousing (easy, see the link above)
Gear ratio changes in the different split t-cases
Flange pattern changes in different split t-cases

 

[Cruiserdrew]

The 38mm's that originally came behind a rig with a spacer (Cdan's computer indicated 4/85' as the cuttoff) will need to tap and plug a hole in the t-case (where a bolt used to attach to the middle of the spacer). I know of a few situations where are guy had a a later model (7/85') with the spacer... but it was a 34mm case

The 38mm case for sure started 4/86. Not in 85.

The spacer started 10/84.

You have to tap and plug that hole in all models of T-case. EDIT: Unless it's an overseas split case that came from the factory behind an H55f. Then no hole to plug.

You also need the long bolts in all models of the split case behind an H55f. Toyota has them new-I got them from Cruiserdan.

Ratios 34 and 38mm cases in the USA are 2.29, escept for the FJ62 cases which may be 1.99. See the recent tooth count posts in the 60s section.

 

[cruiseroutfit]

FJ60 OEM crossmember shortened to fit my FJ40

One last thing... not all 38mm cases had the oiler provisions either... I have a documented case (pictures somewhere) of a 38mm split-case, that doesn't have the oiler

So there are at least 5 varieties of split-cases

80' - ~83' - 34mm idler, no oiler
~83' - ~85/86' - 34mm idler, has oiler provisions, no spacer bolt hole
~85/86' - 34mm idler, has oiler provisions, has spacer bolt hole
85/86' - 87? 38mm idler, has oiler provisions, has spacer bolt hole
87' - 90' - 38mm idler, auto version, vacuum 4wd
85 - 90' - 38mm idler, no oiler (might have been an auto one I had??)

 

[Cruiserdrew]

FJ60 OEM crossmember shortened to fit my FJ40

One last thing... not all 38mm cases had the oiler provisions either... I have a documented case (pictures somewhere) of a 38mm split-case, that doesn't have the oiler

So there are at least 5 varieties of split-cases

85 - 90' - 38mm idler, no oiler (might have been an auto one I had??)

Makes sense-Pretty sure the one behind the auto would not need the provision for the 5th gear oiler.

 

[cruiseroutfit]

The 38mm case for sure started 4/86. Not in 85.

Hmmm... I wish I could find the thread. I used to advertise my kits as -4/86' was a 34mm and 4/86' was a 38mm. However, I ran into a couple customers with rigs having different setups... mabey they were swaps, rebadges, who knows. 4/86' as the cutoff sure agrees with the input gear information I have:
http://www.cruiseroutfitters.com/tech_input_gear.html
(speaking of which I need to fix that unknown?)

The spacer started 10/84.

Toyota system states otherwise oddly... I had always assumed it was earlier. But Cdan looked it up as "April 85' with frame number xxxx." Did I miss a thread where this was hopefully solved?

You have to tap and plug that hole in all models of T-case.

No sir, I surely didn't do it to my case, and I know of other 34's (not bolted to a spacer) that didn't. Look at a non spacer H42, there isn't a spot for a bolt, so if the hole is in the TC, Toyota would have had it plugged from the factory no?
You also need the long bolts in all models of the split case behind an H55f. Toyota has them new-I got them from Cruiserdan.

Ratios 34 and 38mm cases in the USA are 2.29, escept for the FJ62 cases which may be 1.99. See the recent tooth count posts in the 60s section.

Interesting again... I seem to remember another thread where we all hashed this out and figured there were some different ratio's in the mix. The ratios surely are not 100% the same, the input, counter and output gears were different on the pre & post 4/86' (I'm now using that number t-cases... when I get in front of my work computer I will do some more digging.

All good tech, hopefully by the end of the day we'll get the right info

 

[cruiseroutfit]

Makes sense-Pretty sure the one behind the auto would not need the provision for the 5th gear oiler.

Very true... I need to find the pic as I seem to remember it was a 38mm, no oiler, and non-vacuum shift?? Thats why it struck me as an anomoly.

Speaking of anomolies (sp?) there is always the case of the H55F type Toyota 5 speed bolted up to a 1 peice case as shown by a pic in Advance Adapters paper catalogue. https://forum.ih8mud.com/showthread.php?t=64435&highlight=h55f

 

[Cruiserdrew]

On the ratio thing, Jim C or Mark W (don't remember) counted a bunch of teeth. I think the 34 and 38 were slightly different ratios-something like 2.27 vs 2.29. In either case, it confirmed they both contained the desirable and lower ratio gearing, ie NOT 1.99.

You may be right about the non-space split case not having that bolt hole, but I don't think so. I have one in my parts stash that I may have to disassemble just to see if it matters.

I edited my original post just a bit. You may be referring to a non-USA case, not sure. I thought they all had to be plugged and the 2 I have seen did have to be plugged, obviously, you have seen far more than I have.

For the original poster, If you search the 60 section under my user name, I posted a bunch of pics of the hole, the tap and the plug. It's very straight forward and also very important.

 

[cruiseroutfit]

On the ratio thing, Jim C or Mark W (don't remember) counted a bunch of teeth. I think the 34 and 38 were slightly different ratios-something like 2.27 vs 2.29. In either case, it confirmed they both contained the desirable and lower ratio gearing, ie NOT 1.99.

Very good to know All these years we've been wondering

 

[cruiseroutfit]

There is one error in the above diagram. The change to fine spline pinion happened in 1/78. This according to the parts fiche, as well as empirical evidence.

Very correct sir!

I have what I beleive to be the correct vintages here:
http://www.cruiseroutfitters.com/lock_pinion_flanges.html

I didn't draw the picture, honestly I don't know who did... it was courtesy of Trails (thanks again Pablo)

When I get wrapped up on a couple other tech pages (I'm now doing a split-case one ), I'll start modeling the flanges...

 

[cruiseroutfit]

Drew...

Also, I have confirmed the low range of the 38mm manual case, not field tested, just using my books, old threads, and the picture of your case .

Now I need to go dig through my parts and field check the 38mm man. stuff and find the tooth counts on the 34mm stuff

Everything I have leads to say that the FJ62 always had a ~1.99 ratio, BUT it seems that it always had the oiler cup too as there are numerous threads here on mud about guys using their OE 62 TC right off the auto and it had an oiler??

Everything I have thusfar:
http://www.cruiseroutfitters.com/tech_split_case.html

 

[Cruiserdrew]

OK-I'm going to split my 84 case and tranny just to see about that hole. If it isn't there, I'll buy you a beer at Cruise Moab next year. The H42s have that threaded hole, therefore the hole has to be in the t-case to accomidate the bolt.

If the 34mm case in question, came originally behind an H55f like a Canadian model or Aussie model, it wouldn't have the bolt hole. I'll bet that's what you have.

Actually, I'll buy you a beer (or a root beer), hole or not, for all the help you provide to the TLC community.

Pretty sure I'm right about that hole though!

 

[cruiseroutfit]

A killer tech thread
https://forum.ih8mud.com/showthread.php?t=62979&highlight=split+case+h55f

 

[cruiseroutfit]

OK-I'm going to split my 84 case and tranny just to see about that hole. If it isn't there, I'll buy you a beer at Cruise Moab next year. The H42s have that threaded hole, therefore the hole has to be in the t-case to accomidate the bolt.

If the 34mm case in question, came originally behind an H55f like a Canadian model or Aussie model, it wouldn't have the bolt hole. I'll bet that's what you have.

Actually, I'll buy you a beer (or a root beer), hole or not, for all the help you provide to the TLC community.

Pretty sure I'm right about that hole though!

You might be right... I've been racking my brain all day, its been a couple years since I put my TC in, everything I have done as of late has had the hole in need of tapping (they were all 38mm's).

The pic of that no-hole case indeed came from a case that was indeed hooked to a H55f, my bad.... I just reread the thread where it existed.

X-files continues...

 

[cruiseroutfit]

OK... so I am starting to come to the conclusion I was brain dead when assembling my TC because I sure as heck don't remember writing this in regards to my H55F install

(LCML 5/10/01)
I know have all indications saying that I can use any year split t-case mated up to an H55f with some minor modifications. Modifications are as easy as tapping a bolt hole and threading a bolt into it. Anyone diagree? Let me know if you do and why!

Mark W. then set me straight on the oiler cup need.

I'm an idiot...

I'm still holding out hope though... I guess there is a chance that the t-case I pulled off the shelf was indeed a non-US version, I've never even tested the low range ratio, well at least not that I can remember . We did used to buy complete used h55f setups from overseas back then... the case I used may have been previously pulled off one?

I still want to finish up my tech page. If anyone happens to have a split case pulled apart soon.. let me know what year & what you have inside (tooth counts), oiler provision, spacer bolt, etc.

 

[cruiseroutfit]

WAIT...

(LCML, May 9, 2001)
What year cases will work with an H55F?

I have found no difference between the older cases 82ish and the newer cases 86ish except for the 38mm idler shaft and one less bolt from the transfer to the tranny. I have had a few listers tell me that this bolt hole can be plugged and a short bolt can be put through it to make it work. I also have a complete 5 speed with transfer case that only has a 34mm idler shaft in it. Does this mean that older style cases 80-85, can be made to work with the H55F?

Please let me in on the info, I am completely lost on the differences in the cases. Pictures are a great help if available.

Over 5 years ago... amazing I have been able to sleep since then without knowing the truth.

As I remember (my memory is already at trial)... we pulled a dozen or so cases apart that day and found everyone of them had the oiler provision (all were 82' and later it seem). Judging on my statement above I found at least one without the extra bolt... mabey that was the same case I ended up using too? Still could be non-US