H55f output shaft shorter than 4 spd output shaft ??

[amaurer]

Sadly, I think I agree with Rufus - it doesn't look like that gear has anywhere to go, even if you ground the splines.

What are you stacking between the rear transmission bearing and that input gear? The EPC shows nothing, but it looks like you have a spacer in place...? Or is that the case I'm seeing?

 

[RufusTheDufus]

The later (something like 8-82) t-cases got a gear with a seal surface built onto the nose of it and that eliminated the need for the spacer that the seal rides on. Many guys have taken those old gears and put them into newer t-cases though, including me.

I think that's the problem. The gear/spacer are mismatched for the rebuilt t-case.

 

[Beast II]

It is a spacer. This one I think:

33321T SPACER (FOR OUTPUT SHAFT)
90560‑36001 BJ42

Here: ToyoDIY.com

 

[amaurer]

It is a spacer. This one I think:

33321T SPACER (FOR OUTPUT SHAFT)
90560‑36001 BJ42

Here: ToyoDIY.com

No, that spacer is in front of the rear tranny bearing (inside the 5th gear unit).

Look here: ToyoDIY.com

Thats the t/c drawing, and before the input gear its pointing at a spacer that says "refer to 33-05" (thats the transmission drawing, but there is no spacer behind the bearing) and then also references a spacer in a box in the upper left saying it was used up until 10/1982...

36213 STOPPER, TRANSFER INPUT GEAR
36213‑60020 BJ42, FJ40 1 $57.06

The kicker is that the EPC shows this stopper in place for everything! In fact the EPC drawings are labelled 1980-, all the way up to 1987 (which is where i gave up looking). I can't find where this transition lowenbrau mentioned happened.

 

[RufusTheDufus]

BTW, you can jump to fig. 33-05 by changing the URL in your browser from _3610.html to _3305.html

I don't see that part on 33-05.

 

[amaurer]

Maybe this is it....

Your components must be later models than we've been assuming. Check the t/c diagram for a 1987 case (BJ70):

ToyoDIY.com

First off, you can see it uses the gear with the integral sealing surface and no spacers in front of it:
36212 GEAR, TRANSFER INPUT
36212‑60080 BJ70 1 $431.89

(No longer using the 60040/41 gear)

There is a very bizzare note on this drawing for 1985 cases - something having to do with the spacer between the input and pto gears - but there is no part number detail for what the difference is. If you change the date range for the BJ70 in question you can find all of these options for that spacer:
36251 SPACER, TRANSFER INPUT SHAFT
36251‑60030 BJ70 1 $21.56
36251‑60030 BJ70 1 $21.56
36251‑60050 BJ70 1 $22.20

Yes I realize this is not helpful. Sorry, I'm lost.

EDIT:

I read up a little and the H55f was used FAR later than even this. If you check the listing for a 1997 HZJ7*, you find this:

http://www.toyodiy.com/parts/p_G_1997_TOYOTA_LAND+CRUISER_HZJ70RV-MR_3610.html

Input gear changes to
36212 GEAR, TRANSFER INPUT
36212‑60110 HZJ7*..HT..GEN; HZJ75..ARL, GCC; HZJ75..GEN..IV; HZJ75..LHD..PIC..GEN..CBU 1 $560.35

And an oring is added in front of it (no spacer)
6212J RING, O (FOR TRANSFER INPUT GEAR)
90301‑34005 HZJ7*..HT..GEN; HZJ75..ARL, GCC; HZJ75..GEN..IV; HZJ75..LHD..PIC..GEN..CBU 1

I think you need to buy a whole set of gears from a transfer case that was originally behind an H55f - I certainly can't help you tease out what the differences are so you can replace only some.

I'll shut up now.

 

[RufusTheDufus]

Beast - I'm trying to understand your parts. The aluminum bolted to the back of the H55 is new? The balance of the components for the transfer case are from your 4 speed setup?

Is the input gear (and rest of the output shaft gear stack) in the photos from the transfer case that was in your truck? You bought a transfer case rebuild kit from 4wheelauto for your existing/original transfer case or a different one that was purchased with this swap in mind? In your photos you label the transfer case "5 SPD transfer case shell". I'm assuming that this is not the case that was in your BJ42 with the 4 speed.

 

[RufusTheDufus]

He just called me and said that the output shaft on the new H55F is approx. 3/4 inch shorter from the rear transmission bearing to the end of the shaft than that of the original 4 speed, which puts the bearing in a different spot and things get misaligned.

I overlooked this. It's important. The shaft is shorter when measured from the rear transmission bearing. It's a shorter shaft. It must need the newer type of input gear that doesn't need the oil seal spacer.

Is there a part number on the transmission that will help identify the year? If it's not on the tranny it may be on your receipt.

 

[crushers]

you are making this way harder than it needs to be...
you use the original 4 speed input gear and everything else is the 5 speed case guts. or is it you use the 5 speed input gear and the rest of the guts of the 4 speed... s***, mind fart.

take a pic of the both imput gears side by side and post them up. i want to see the tranny side of the input gears from the side of the gears. the 5 speed should have a machined surface on the tranny side and the 4 speed should have a cast surface... you want the machined input gear for this swap...that i know...

oh, oh, oh, i got it now. the input gear has to have the machined surface of the 5 speed case and the rest of the gears in the t/case can be either the 5 speed case gears (1.96/1 crawl) or complete 4 speed case gear set (2.3/1 crawl with 81 or 82 vintage gears set) . if you use the 4 speed gear cluster then you MIGHT end up with gear whine/howl due to the mixing of the input gear with the idler gear both of which wore into other gears but you will end up with better crawl.

as for the length of the shaft, you worry too much. if you use the proper input gear then the actual length of the input shaft is irrelevant. it is close enough not to matter. the important thing is the gear meshing. just before the rear case goes over the mess the input gear should line up PERFECTLY with the idler gear and that should line up PERFECTLY with the output gears. THAT is the important part...

do you have the smaller idler or larger one?

BTW, the PTO gear MUST go in the right direction since the gears on the PTO and the drive gear come close but do not grab properly if the drive gear is in backwards. ask Lowenbrau about this one. the PTO drive gear is NOT reversable...

if memory serves me well. i have done many of these swaps over the years but am concentrating on the HZ build.

 

[GLTHFJ60]

take a pic of the both imput gears side by side and post them up. i want to see the tranny side of the input gears from the side of the gears. the 5 speed should have a machined surface on the tranny side and the 4 speed should have a cast surface... you want the machined input gear for this swap...that i know...

oh, oh, oh, i got it now. the input gear has to have the machined surface of the 5 speed case and the rest of the gears in the t/case can be either the 5 speed case gears (1.96/1 crawl) or complete 4 speed case gear set (2.3/1 crawl with 81 or 82 vintage gears set) . if you use the 4 speed gear cluster then you MIGHT end up with gear whine/howl due to the mixing of the input gear with the idler gear both of which wore into other gears but you will end up with better crawl.

do you have the smaller idler or larger one?

BTW, the PTO gear MUST go in the right direction since the gears on the PTO and the drive gear come close but do not grab properly if the drive gear is in backwards. ask Lowenbrau about this one. the PTO drive gear is NOT reversable...

Because the two cases have different crawl ratios, wouldn't all of the innards have to be from the same case? Or are the input gear, large idler gear and small gear on the output shaft the same for all versions of the split case?

In the later cases, the FSM shows that the longer side of the PTO gear must be facing the transmission, which defines it's orientation.

 

[crushers]

the input gear has the same tooth count and pitch for both.
the high range idler gear has the same gear tooth count and pitch for both
the change is the lower (smaller) idler gear tooth count.

 

[Beast II]

Spector tells me that I need a more recent transfer case to work with the H55F. Thoughts ? It looks like the shell of the transfer case is just a bit too wide. Is mine an H41 or H42 ?

I'm getting desperate now as 4wheel auto hasn't called me back in 3 days and my BJ42 has been in the shop - - waiting - - for almost a month. Obviously I need some different parts. What parts and where ? What transfer case generally works with the H55F and will it work in a BJ42 ?

I'll name my first born after you

 

[amaurer]

You've got an H41. Easy test - is first gear almost annoyingly low? If yes then its an H41

 

[crushers]

any split case will work between 1982 and 1985, you will need the front half (at least) of the 5 speed t/case for the 5th gear oiler. the 4 speed or 5 speed rear case from above years will work.
the only difference between the 82-85 split case and the next generation is the idler shaft size. the over all sizing of the case is the same.

what is the problem now?

 

[crushers]

the overall size of the H41 and the H42 is the same. the only real difference is the first gear is bigger when comparing the 2 units. the H55F has the exact same gearing as the H41 plus the O/D.

 

[Beast II]

Since Toyota still sells the H55F new, I'd guess they still sell the matching transfer case new. Would this fit and work with a diesel ?

I am a complete tranny/transfer case novice, so I appreciate all of the help. I need to get my Cruiser out of the shop.

 

[crushers]

holy crap, i hope you are sitting down for the $$$$ of the t/case.
IF you are going this route then contact Dave at Japan 4X4 (tell him Crushers sent you) and get a quote from him.

where do you live?

 

[Beast II]

I live in California in the Santa Ynez Valley.

Sheldon at G&S told me that all JDMs are vacuum shift and that the actuator diaphragm on the transfer case interferes with the frame rail. He said that the manual shift case out of a post 85 FJ60 or 85-87 BJ70 would work (but he didn't have one), so I just bit the bullet and ordered the whole setup from SOR along with a rebuild kit. You were right about it being expensive, but hey its only money, they'll print more

 

[70sguy]

You did specify that it had to be manual shift front drive Case right?

 

[Beast II]

You did specify that it had to be manual shift front drive Case right?

The SOR tech guy, Kurt called my mechanic directly to get all of the specifics, so I should be in business.

Thank you for helping me out Mud and everyone on it has been an amazing resource for many years.