H55/split case into a HJ47 Troopy

[82cruiser]

82Cruiser, did you end up swapping the existing transmission brake to the back of the donor transfer case? If so, was this a relatively easy operation?

Hi Mark,

We swapped a TC ebrake onto the other case which was pretty straightforward. If you have a FSM you should be able to do this. While the ebrake will clear the cross member, it is a very tight fit. I chose to relocate my cross member farther back on the frame which made install much easier and removal in the future will be easy as well.

I think that the TC ebrake is a little more reliable as you don't have to worry the rear drum brakes rusting.

 

[orangefj45]

I think that the TC ebrake is a little more reliable as you don't have to worry the rear drum brakes rusting.

i'm gonna have to respectfully dis-agree on this one.

the stock t-case mounted parking brakes are marginal at best. it just does not have enough holding power.

the fj6x series ebrake works excellent, bar none.

 

[82cruiser]

Agreed, the TC brake does not hold as well. Just commenting on the reliability. I've had the wheel e-brakes freeze/rust up a number of times as compared to the TC e-brake.

 

[dingbatt]

Thanks for the help Orangefj45 and 82cruiser.

I'd have to say if I could pick one over the other, it would have to be the wheel park brake. If they do freeze / rust up (probably not as much of an issue here in Australia) they are a lot easier to get to and repair, rather than having to get under the car, remove the drive shaft and drain the t-case before even inspecting the brake mechanism.

For me, its just a matter of parts availability and work involved in swapping to the wheel park brakes. Has anyone done this before? if so, what is involved?
I'm guessing rerouting an extended cable to the rear drums, and replacing the existing backing plates with those from a 60 series..... anything else?

Cheers,

Matt

 

[orangefj45]

once again, i'm gonn ahave to put in my $.02's worth.

i have worked on a few cruisers for customers as well as having owned more than 30 of them.

the ebrake on the t-case is a lot less reliable than the counterpart on the rear axle IMHO.

here's why i don't like the t-case mounted parking brake as well:
1) we've all done this: driven off with the ebrake on. after 1/4 mile you finally figure it out but by then the shoes are glazed and the brake never holds as well as it used to. so it's time for new shoes.....
2) tendancy fot the rear t-case seal to wear into the drum brake seal surface causing a leak. now you need to replace the brake drum or put a speedy sleeve on it. nevermind the shoes getting a nice "oil bath" when this does happen sop now you're buying shoes as well........
3) simple physics. take a look at the size of the brake shoes. now look at the shoes on the axle mounted brake.
4) more physics; leverage. would you rather have the holding pressure applied at the wheel or on the driveline ( and at least 3 sets of splines upstream.....)
5) more physics; poor leverage on the early hand operated handle.
6) cables love to get too close to the exhaust and or trans and wear out.
7) parts availability; sure you can get shoes at spectre and a few other cruiser specific vendors, but try buying them at your local auto parts store.......
8) i'll stop there

and fwiw, i have yet to see a 60 series ebrake setup that's frozen up unless it's been sitting a long time. then again, i do live in CA so we don't have to deal with snow, ice and salt on the roads as much as the guys on the east coast. but i believe those factors would affect either setup the same.

if all that does not convince you. get in a 60 with the ebrake on and see if you can take off in 2nd gear. now do the same thing in a rig with the t-case munted ebrake. enough said.


as for installing the axle mounted brake on your hj, you should be able to remove the needed parts from an HJ6x series rig and bolt them up. i believe the brake cables will work as well. you will need to weld a couple of brackets on the rear axle housing. they act as giudes and mounts for the cable and mechanism. simple swap and well worth it imho.

hth

georg @ valley hybrids

 

[fogblanket]

I have never had much luck with the axle mounted drum parking brake. the rear drums get jammed up so fast in the northeast that it is an every other month maintence to keep them working right. one of the first mods I do on any new cruiser that is going to be a daily driver is to switch to rear disk brakes. not becasue of them braking better because a correctly set up drum brake is nice but to have a more reliable type set up on the rear. I had the best when I ran an fzj80 rear axle on my fj62 in that the parking brake setup was on the inside of the rear disk brakes but on the 40 series axles if you switch to rdb your only option is the t-case e-brake or the elderado calipers (which I have not run but hear they are finicky as well). even if you have to change/clean the tcase brake out once a year, to me that is far better than the 6 times a year you have to clean out the drum brakes. or more if you 4 wheel regularly. we have alot of muddy murky water crossings on our trails and not cleaning out your drum brakes after these water crossings can led to troubles down the road.
just my 2 cents
jason

 

[Chamba]

Dingbat,

I agree with Orangefj45: unless you are beaching your rig regularly, the reax axle handbrake is far, far, far superior to transfer case-mounted unit. Granted, in the NE the rear axle rusts up and becomes useless, but this is not an issue in either Australia or anywhere west of I-25 or south of I-10 in the US.

For you, given you are in Oz, look for a transmission floor cover from an 82-84 40 series. Also look for a 40 series top loader for the 5 speed out of an LX or 5 speed-equipped FJ40/BJ42 (or simply get the whole uinit out of that rig). When you find this rig, it will have a full floater rear axle with the handbrake already installed on the rear axle (any 81-84 FJ40/BJ42 should have this rear axle, irrespective of whether or not it has a 5 speed). You can simply take that axle out. Or, get the backing plates, etc. from a 60 series as Orangefj45 suggests- too easy.

If you put a 60 series 5 speed in without changing the top loader, than you will have interference issues with the handbrake and the tranfer case shifter, as 82cruiser did (this is only an issue with RHD 40 series, BTW). By putting the 40 series top loader in (and using the associated tranfer case shifter linkages), you will avoid this. I hope this helps.

Cheers,

Josh

 

[fjwagon]

This is a very good thread seems everything is covered. I have done a 5 speed conversion using a 5 speed top plate from OZ on a 82 US fj40. This is the way to go if you can locate one. As far as the ebrake is concern, you can get the ebrake cable assy( all one piece) and replace it if you are going with a newer 40 axle.....fullfloater would be nicer in my opinion. If I live in Australia I would do what HJ47 is recommeding. As far a the mod to the bell housing there is nothing to it. Just have a grinder handy when you get ready to mate the tranny and grind off what is in the way on the bellhousing. And side note I don't remember which fj60 transfer lever I used. I had originally used the one off the fj40 by bending it but did not function as well as I thought it should of. Anyhow, the lever I ended swapping it with came from....I believe...a 85-86 fj60 one. I hope someone can chime in confirm it.

 

[JohnnyC]

Randy great job...love the work you do.

I have nothing to add other than...next time look out for the sharp edges

 

[dingbatt]

Man, this thread just keeps getting better.... Thanks for all the input guys, its making my life a whole lot easier!

That's a really good suggestion with the transmission floor cover josh, that had never occurred to me. I'll be keeping my eyes peeled for '82+ FJ40/BJ42 parts in the local trader.

I bought myself an H55F about a week or so ago from a guy who had pulled it out of his HJ75 when he did a 350 conversion. Will the interference issues with this toploader and transfer lever be the same for this as it would for one from an HJ60?

I recently replaced the rear axle with a rebuilt one about 4 months ago, so I'm a little hesitant to go replacing it so soon. But I guess if I have to weld brackets on this one to run the handbrake lines, it may just be easier to swap to another 40 axle with the handbrake lines already installed. I'll have to have a look at a 60 series rear axle and see what's involved in emulating its bracketry!

 

[orangefj45]

I bought myself an H55F about a week or so ago from a guy who had pulled it out of his HJ75 when he did a 350 conversion. Will the interference issues with this toploader and transfer lever be the same for this as it would for one from an HJ60?

yup, it'll have the same top cover as the 6x series h55f. i would be interested in one or two of the 4x series h55f top covers if you come across them, i'm working on a troopie with an h55f swap as well as having one sitting on the shelf for my personal hj47........so please keep me in mind.

 

[82cruiser]

Randy great job...love the work you do.

I have nothing to add other than...next time look out for the sharp edges

Thanks much Johnny! Good advice, my 4 year old son gave me the bandaid.

 

[dingbatt]

i'm working on a troopie with an h55f swap as well as having one sitting on the shelf for my personal hj47........so please keep me in mind.

Will do

Thanks for the help everyone.

I'll keep you posted when I do get around to the installation.

Cheers,

Matt

 

[DanS HJ-45]

yup, it'll have the same top cover as the 6x series h55f. i would be interested in one or two of the 4x series h55f top covers if you come across them, i'm working on a troopie with an h55f swap as well as having one sitting on the shelf for my personal hj47........so please keep me in mind.

You and me both buddy! I called SOR a bit back just to gawk at how pricey one was, and they insisted that it was not possible to get one. At any price. I say I just need to look harder... As long as I beat you to it....

Dan