Builds H55/Splitcase into 02/79-40 Series

[Hugh Heifer]

Poser, on the crossmember, I think you just mentioned it to be a "late." to you recall the year. I was looking at an '84 60 model crossmember and I understand they are different but was wondering what year you used and if the earlier (between frame style) could be used as well.

 

[DomSmith]

mini-hijack

Hugh-

If you're talking about the tranny cross member the differences can be seen here:

the upper gray is the NEWER FJ60 cross member that I don't think you want. Too much work for a 40 IMO.

The lower black one is EARLIER (this one is an 85).

 

[Hugh Heifer]

Thanks Dom,
I continued to search and just found that pic and it made things clear. Seems the ticket is the earlier crossmember with the '85 and on split transfercase and that will get you rolling with just the usual tool throwing and f bomb dropping!

 

[79BJ4T]

Poser:

I have a 1979 BJ40 with the 4 speed tranny. The rear mount is actually underneith the clutch bell housing, not under the tranny. Is that what you refer to earlier? In that case am I OK or do I need to add a crossmember below the transmission. I assume the 5 speed is around a 100 pounds heavier and all that's cantilevered on the bell housing.

2 questions:
How much longer is the H55 than the H42?
How much do the shifter holes move back?

Thanks,

 

[matt.mcinnes]

2 questions:
How much longer is the H55 than the H42?
How much do the shifter holes move back?

Thanks,

79mm springs to mind or 3.11"

 

[Radd Cruisers]

John is using a Tuffy center console so I had to mod the shift cane a bit...

Kool thread, just came across it.

We use to melt the rubber in the shifter arm and slide the two apart then head the lower portion with a torch and bend to fit, then expoxy the upper part of the shifter back onto the lower section.

Also my favourite cross member was the 60 series that fit up inside the frame like yours, we used nutserts and have not had one failure.

We do the same thing with the shifter cover.

Someone asked if about the top shifter assembly and I think toyota had three versions, one for the 60 series 40 series and 70series if I am not mistaken.


One of your posts shows the skid plate, would or could it have been incorporated into the transmission mount?

Rob

 

[PabloCruise]

I wanted to add this link to a rear counter shaft bearing repair:

https://forum.ih8mud.com/40-55-series-tech/365205-h55-noisy-through-shifter.html

 

[Living in the Past]

I have few questions about this. Would this have been easier without the rear brake drum? Now that they have become unavailabel the only real option is the later axle with the hand brake. Did you prefer the hand brake on the back of the transfer case? Would the lack of the hand brake allow the transmission/transfer case to use the stock crossmember on the 81 and later models? Is the clearnce with the gas just with the hand brake or with the Transfer case also? If so is this clearance issue front to back or top to bottom. Lastly is the mounting point on all H55F the same as on my 82 H42 transmission? On the A440F is is much further back. Thanks

John

 

[FJ40Jim]

I have few questions about this. Would this have been easier without the rear brake drum?

IMO, it is an easier/better swap using a 81-later 40 series rear axle w/ p-brake in the rear drums.

Did you prefer the hand brake on the back of the transfer case?

No. It can be made to work pretty well, but never as much holding power as properly functioning 81-later drums.

Would the lack of the hand brake allow the transmission/transfer case to use the stock crossmember on the 81 and later models?

I dont understand? 81-later FJ40 has the x-member that H55 mounts to. That part is done for us at the factory.

Is the clearnce with the gas just with the hand brake or with the Transfer case also? If so is this clearance issue front to back or top to bottom.

IME, it is very tight between t-case/output flange and tank. I didn't try it w/ H55 & t-case P-brake. In both cases, the fuel tank got the flange beat flat and the area behind the t-case lightly massaged.

Lastly is the mounting point on all H55F the same as on my 82 H42 transmission? On the A440F is is much further back. Thanks

Yes, 81-later H4x & H55 are the same until the tail of the trans. The front end and transmission case mount the same. Only the back of the H55 is longer, which pushes the t-case back against the fuel tank & x-member.

 

[Living in the Past]

[IMO, it is an easier/better swap using a 81-later 40 series rear axle w/ p-brake in the rear drum.
No. It can be made to work pretty well, but never as much holding power as properly functioning 81-later drums.]

That's what I thought just wondering why a later axle wasn't used. Just wanted to make sure I wasn't missing something.

[I dont understand? 81-later FJ40 has the x-member that H55 mounts to. That part is done for us at the factory.]

My question is can the crossmember be used just as it is. I see where Steve welded the brackets lower than stock for the crossmember. Wanted to know if this was done just becaues of the hand brake clearance issue.


[IME, it is very tight between t-case/output flange and tank. I didn't try it w/ H55 & t-case P-brake. In both cases, the fuel tank got the flange beat flat and the area behind the t-case lightly massaged.]

Thank you just what I was asking. It's a front to back clearance problem.


[Yes, 81-later H4x & H55 are the same until the tail of the trans. The front end and transmission case mount the same. Only the back of the H55 is longer, which pushes the t-case back against the fuel tank & x-member.[/quote]


The A440F mount to the crossmember is just infront of the transfer case. The crossmember mount on my 82 H42 is just behind the bell housings. Asking is it in that location on the all H55F.

I guess another thing I would want you do is use a 2f bell housing not one from a 3F since they clock the transmission/transfer case down on the passenger's side and the H42 crossmember won't work. Right. Or is the H42 crossmember wrong for the H55F and the crossmember mount different?


My over all question is since I have the later axles to work will all I would need to do to is modify the front flange on the gas tank? Modify the shifter plate and modify the drivelines? I do realize there might is something small that has to be done to certain transfer cases.

 

[Hugh Heifer]

My question is can the crossmember be used just as it is. I see where Steve welded the brackets lower than stock for the crossmember. Wanted to know if this was done just becaues of the hand brake clearance issue.

Yes and it was also 2/79 so it did not have the crossmember in place already.

I guess another thing I would want you do is use a 2f bell housing not one from a 3F since they cock the transmission/transfer case down on the passenger's side and the H42 crossmember won't work. Right. Or is the H42 crossmember wrong for the H55F and the crossmember mount different?

It is just like 5%. I used the 3f.

 

[Eqcruiser]

Hello someone know where can be found the rear bearing retainer used in the h55 splitcase to save my h41 parkbrake

 

[Eqcruiser]

This the retainer from this project pictures

 

[Hugh Heifer]

What was used in this install was provided by Man a Fre in an aftermarket kit they used to sell. The kit was discontinued years ago.

 

[KY Longhunter]

Question: I’ve got a May 1979 Frame and a complete 2F/H42/Split Case out of an Dec 1986 FJ60.

I also have an ‘79ish Bellhousing for H42 with tabs/ears to mount on frame.

Would it be easier for me to swap Bellhousing and utilize the Bellhousing to Frame mounts, or utilize the FJ60 crossmember and weld onto frame?

 

[4Cruisers]

With the longer H42 (post-4/85), the transmission/transfer case is going to cantilever out well beyond the bellhousing. IMO you'll want to use a crossmember to support the weight that far out.

I'll be installing an early '80s H41 with split transfer case into my '71 FJ40 (has already been modified for a '78 FJ55 H42 with one-piece transfer case), and will use the bellhousing to frame mounts for support - no crossmember. I took some measurements and discovered that the new transmission/transfer case combination is ~1/4" shorter than the FJ55 combination.

 

[PabloCruise]

Hey Alan-


The cross member that attaches to the underside of the transmission was not installed in a 40 series until 08/80, when they went to the 19 spline H41/42 transmission and split transfer case, different spring/shackle hangers, parking brake on the semi-float rear axle assemblies, among other things.

I have a later model cross member assembly that I am going to install in this truck and remove the mounts on the sides of the flywheel housing.



-Steve

Yes, I realize this post is 17 years old.

Why not keep the mounts on the sides of the bellhousing/flywheel housing?

Belt + suspenders approach...

EDIT - now I understand, so you can lower things to clear the frame crossmember.

 

[PabloCruise]

So,


Sunday I was going to try and make some real progress on this...


Needed to modify the flywheel housing to work with the input bearing retainer of the H55...



Pictures show the input bearing retainer from the H55 and the areas where the flywheel housing need to be opened up. I marked those two spots with a pink paint pen, and then got after them with a 90 degree die grinder with a carbide tool. It made pretty quick work of the areas that needed to be removed.
View attachment 125393View attachment 125394View attachment 125395

Great pictures - thanks. I forgot you need to notch the bellhousing for the H55...

 

[PabloCruise]

I will take lucky over good any day.

Yep...

 

[PabloCruise]

Yes it will.



As far as I know, the oil pump in the picture should be exactly the same as what you will find in your 2F engine.



One thing on removing the Phillips head fasteners that retain the aluminum pick up and lower half of the oil pump:



I used a Snap-On #3 Phillips that has a 7/16” wrench hex on it by the handle, along with someone pushing down on the top and helping turn the fastener, as these were not going to simply come out. I also used a hammer and seated the screwdriver into the fasteners, and had to use a flat punch to try and repair/make flat again the Phillips head of one fastener in order to get them all removed. That is why I now have installed hex head fasteners when I reassembled the pump and pickup body.


If you do not own a quality screwdriver, you will want to purchase one, at the very least, a Craftsman Pro Series or something equivalent. Trying to remove these fasteners when the head is stripped would not be fun at all.



Good luck!


-Steve

JIS fastener, yes? So a JIS driver will help greatly...