Need Advice: 1974 FJ40 4-Speed Transmission rebuild or replacement options (1 Viewer)

Joined
Dec 30, 2014
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Franklinton, NC
I need help/advice with my many questions about my FJ40 transmission. I have a 1974 FJ40 4-speed transmission roars (sounds/feels like bearings are gone, comes and goes at speeds over 40 mph) and I had a local transmission guy confirm it needed a rebuild. He said parts were discontinued and he couldn't help me. I would prefer to pay someone to rebuild it if was at a reasonable cost. I would even be willing to pay a little bit more if the 5-speed swap was an option but I'm not willing to pay more than the value of the vehicle itself. While doing research on this, I don't see many people rebuilding the 4 speed. I've been able to find a few original used transmissions that people claim are good but I'm concerned about being in the same situation after a week or so of running a transmission that has been full of rain water for 30 years.

What is everyone else doing when their transmission needs a rebuild? I'm open to anything but if I'm looking at $3k+ for a rebuilt 4-speed then I'm going to consider an engine/driveline swap and I know nobody here wants to see that, right?

Should I plan on a transfer case rebuild while I have it out or can that wait until it becomes a squeaky wheel?

Does anyone offer a local or mail-in rebuild service? Local to Raleigh or I can ship it to them. If needed I can remove and reinstall myself but I've had a few back surgeries and prefer to outsource if possible.

What is the best direction to go in my situation?
1. rebuild 4-speed?
2. install new/used 5-speed of some sort? I've read that new driveshafts might be needed? How about transfer case? etc?
3. Are there any trans/t-case swaps that come from any other models? 4runner, pickups, the "J-word", etc?
4. For option 4, I'm hoping you guys have already been getting creative and I'm just not finding the answer in my searches.

I'm located near Raleigh, NC.

Any help and/or advice is greatly appreciated!
-Doug
 

flx

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Transmission on a 74 is noisy. Mine also have a noise at some specific speeds (or probably engine rpm) but as long as it's working fine (and sound is not unbearable) I think you best course of action is to do nothing and enjoy your FJ40.
 
Joined
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Messages
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Franklinton, NC
Transmission on a 74 is noisy. Mine also have a noise at some specific speeds (or probably engine rpm) but as long as it's working fine (and sound is not unbearable) I think you best course of action is to do nothing and enjoy your FJ40.
It's pretty unbearable. It's slowly gotten worse but I'm afraid to drive it over 40 mph. Sounds like it's going to grenade if I keep pushing it.
 
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I need help/advice with my many questions about my FJ40 transmission. I have a 1974 FJ40 4-speed transmission roars (sounds/feels like bearings are gone, comes and goes at speeds over 40 mph) and I had a local transmission guy confirm it needed a rebuild. He said parts were discontinued and he couldn't help me. I would prefer to pay someone to rebuild it if was at a reasonable cost. I would even be willing to pay a little bit more if the 5-speed swap was an option but I'm not willing to pay more than the value of the vehicle itself. While doing research on this, I don't see many people rebuilding the 4 speed. I've been able to find a few original used transmissions that people claim are good but I'm concerned about being in the same situation after a week or so of running a transmission that has been full of rain water for 30 years.

What is everyone else doing when their transmission needs a rebuild? I'm open to anything but if I'm looking at $3k+ for a rebuilt 4-speed then I'm going to consider an engine/driveline swap and I know nobody here wants to see that, right?

Should I plan on a transfer case rebuild while I have it out or can that wait until it becomes a squeaky wheel?

Does anyone offer a local or mail-in rebuild service? Local to Raleigh or I can ship it to them. If needed I can remove and reinstall myself but I've had a few back surgeries and prefer to outsource if possible.

What is the best direction to go in my situation?
1. rebuild 4-speed?
2. install new/used 5-speed of some sort? I've read that new driveshafts might be needed? How about transfer case? etc?
3. Are there any trans/t-case swaps that come from any other models? 4runner, pickups, the "J-word", etc?
4. For option 4, I'm hoping you guys have already been getting creative and I'm just not finding the answer in my searches.

I'm located near Raleigh, NC.

Any help and/or advice is greatly appreciated!
-Doug
Hey, I don't know if I can help but I do have an extra 4 speed for sale if you decide to replace it! Just let me know.
 
Joined
Dec 30, 2014
Messages
35
Location
Franklinton, NC
You can get all the parts from vendors on this forum to rebuild the transmission and transfer case. You can supply a shop or use the info on this forum to DIY.

I was reading this but when I clicked on the vendor websites that were mentioned the only parts that I was finding were the seal and bearing kits but I only looked surface deep, I'll contact a few and confirm that input/output shafts are still available.
 
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Helena MT
IMHO I would find a good used trans and install it, IIRCC the 74 depending on when it was made could be a 3 speed transfer which will be noisier than the later years transfer case, but the 3 speed transfer has a lower low range.

5 speed swap is out with your budget
 
Joined
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22,077
IMHO I would find a good used trans and install it, IIRCC the 74 depending on when it was made could be a 3 speed transfer which will be noisier than the later years transfer case, but the 3 speed transfer has a lower low range.

5 speed swap is out with your budget


The earlier four speed transfer case up to 4/75 has a wider gear on the low range part of the idler shaft and Low range gear. The low range gearing in the four speed up to 4/75 is the same as 4/75-7/80 four speed. High range is still 1 to 1 but gear count changed on high range gears changed 4/75 which along with wider gears may contribute to it being quieter. Only real advantage of these transfer cases is the input gear that allows three speed transfer case to be used on four speeds.

Besides looking this up I have a couple of the early four speed transfer cases and personally verified it. My 79 has one of these cases and picked up a transmission and transfer case out of a 78. Turns out the transfer case is another 74 case. Wonder if they were changed because the original transfer cases were bad or because they thought they were getting a lower low range. Common belief these cases had lower low range.
 

flx

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1971-1974 Chassis FSM specifies that the transfer is 2.3 even on the 4 speed:
1664263989362.png


While the 1975 Chassis FSM specifies a different ratio:
1664264321496.png


On the EPC there are multiple references for both the 3-speed and 4-speed all along with PN change on 09/72, 09/73, 01/74, 01/75 and 04/75.... This isn't helping much to know when it changed.

The 1971-1974 FSM also only mention a first gen H41 for the 4-speed while the 1975 has both the H42 and H41 (with 2nd gen ratios) listed. So maybe the change on the transfer ratio happens at the same time than the change on the H41 ratio and availability of the H42...
 
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ToyotaMatt

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I need help/advice with my many questions about my FJ40 transmission. I have a 1974 FJ40 4-speed transmission roars (sounds/feels like bearings are gone, comes and goes at speeds over 40 mph) and I had a local transmission guy confirm it needed a rebuild. He said parts were discontinued and he couldn't help me. I would prefer to pay someone to rebuild it if was at a reasonable cost. I would even be willing to pay a little bit more if the 5-speed swap was an option but I'm not willing to pay more than the value of the vehicle itself. While doing research on this, I don't see many people rebuilding the 4 speed. I've been able to find a few original used transmissions that people claim are good but I'm concerned about being in the same situation after a week or so of running a transmission that has been full of rain water for 30 years.

What is everyone else doing when their transmission needs a rebuild? I'm open to anything but if I'm looking at $3k+ for a rebuilt 4-speed then I'm going to consider an engine/driveline swap and I know nobody here wants to see that, right?

Should I plan on a transfer case rebuild while I have it out or can that wait until it becomes a squeaky wheel?

Does anyone offer a local or mail-in rebuild service? Local to Raleigh or I can ship it to them. If needed I can remove and reinstall myself but I've had a few back surgeries and prefer to outsource if possible.

What is the best direction to go in my situation?
1. rebuild 4-speed?
2. install new/used 5-speed of some sort? I've read that new driveshafts might be needed? How about transfer case? etc?
3. Are there any trans/t-case swaps that come from any other models? 4runner, pickups, the "J-word", etc?
4. For option 4, I'm hoping you guys have already been getting creative and I'm just not finding the answer in my searches.

I'm located near Raleigh, NC.

Any help and/or advice is greatly appreciated!
-Doug


your BEST option and MOST practical one would be to Contact @cruisermatt who owns and operates CruiserMatt's OFF ROAD in Winter Park Florida


- he is close to you in NC ,

- he will educate you on your options and services he provides , and you can then make a more well informed Decision


- when you consult with Experts , you get Expert Advise , Bottom Line






1664266705077.jpeg
 

orangefj45

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norcal
We have rebuilt H42 4-speeds in stock and ready to ship.
We also stock the rebuild kits, synchro rings and other components for these.
Along with that, we also stock all the components needed to rebuild the transfer cases.
Happy to help.

Georg @ Valley Hybrids @ Cruiser Brothers
Shop 209-475-8808
Sales@valleyhybrids.com
 

POPO AGIE

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Riverton, Wyoming
I rebuilt a 4-speed and the transfer case with readily available parts. I even was able to get the input and output shafts so they could be replaced. With a FSM manual from Toyota and this forum they is a lot of help out there to get you through the rebuild.

I sold the transmission and transfer case to another member and I have an H55F 5 speed and split transfer case that I will install in my 78 FJ40.
 
Joined
Apr 21, 2005
Messages
22,077
1971-1974 Chassis FSM specifies that the transfer is 2.3 even on the 4 speed:
View attachment 3125398

While the 1975 Chassis FSM specifies a different ratio:
View attachment 3125399

On the EPC there are multiple references for both the 3-speed and 4-speed all along with PN change on 09/72, 09/73, 01/74, 01/75 and 04/75.... This isn't helping much to know when it changed.

The 1971-1974 FSM also only mention a first gen H41 for the 4-speed while the 1975 has both the H42 and H41 (with 2nd gen ratios) listed. So maybe the change on the transfer ratio happens at the same time than the change on the H41 ratio and availability of the H42...


Finally got around my 74 four speed transfer case. It is like Amayama lists. Low range gear has forty teeth, not forty-three like the three speed. Has the wide low range gears and the rest are narrow.
20221012_163610.jpg

Date is May of 1974.
20221012_163318.jpg

The case has the provision for the shift linkage on the housing for 2WD/4WD shaft.
20221012_163618.jpg
 

flx

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Messages
720
Location
France
Finally got around my 74 four speed transfer case. It is like Amayama lists. Low range gear has forty teeth, not forty-three like the three speed. Has the wide low range gears and the rest are narrow.
Good catch! I checked the paper Master catalog and it says the same than the EPC. So it seems the Toyota made an error in the FSM?


Where is located the date stamp on the transfer case?
 
Joined
Apr 21, 2005
Messages
22,077
Good catch! I checked the paper Master catalog and it says the same than the EPC. So it seems the Toyota made an error in the FSM?


Where is located the date stamp on the transfer case?

Person did a sloppy job stamping the date number made code. 4 is where it should be but the E for May is on the lower right versus next to the 4. This on the right side of the case towards back in a small flat section. Think I have another one of these cases some where in the garage this one is in. Plus my 79 has one installed.

Can't comment on the FSM. Have a feeling that is why my 79 has one and possibly the 78 as well. I know low range is nothing like that in my 68 with a H42 and original transfer case. 79 has the 3.70:1 diffs. What are you going to do after going to the trouble of finding the rare early four speed transfer case and install it only to find it wasn't any better? Would you go thru the work of putting the original case back in? Wasn't that easy finding part numbers with specs in the last century. Guy behind the counter probably wasn't any help. All the customer know was the FSM showed it lower gearing like the three speed. I haven't checked my Haynes manuals. I didn't have one of those until the early eighties. Can't remember when I bought my first FSM. I do remember thinking the early four speed split case had lower gearing.
 
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If you are still looking, I have a good 4 spd and 4spd t-case combo up here in Richmond, VA. I can set you up with the proper yokes to mate your driveshafts up too. About 3 hours away.
 

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