Old Yella gets a 5th gear!

[dingbatt]

G'day all,

My troopy, "Old Yella", will be getting an H55F with split case in the near future. I've planned this ever since I bought the old steed about a year and a half ago. But a couple of months ago she lost mobility, and has been parked out the front of my house ever since. The inner Hi/Lo range selector lever had become disengaged from the clamp on the outer lever and dropped into the T-case. So this meant it was a perfect time to put in that H55F that I had sitting out the back for ages.

So I've been doing my research (mostly here on MUD), collecting the bits required, and cleaning and repainting the gearbox - yes, it's blue. I wanted something a bit different. Probably shouldn't have bothered painting the bellhousing in hindsight though. I actually quite like the result:





There's just a few queries I have before I get Old Yella towed to the workshop where the swap will be done.

Firstly, I am in the process of selecting a clutch kit - I'm going to change it while I'm there. I've got a few prices, I can get an Exedy clutch kit for $299; most other aftermarket kits are around that price or more. An aftermarket Heavy duty kit is about $600, but I don't think I'll need that as I don't plan on squeezing a mighty V8 or anything under the bonnet ever. A genuine Toyota kit is $550. What do you guys reckon? Stick with Toyota? has anyone had any experience with some good aftermarket kits or any reccomendations?

I am going to be changing the park brake (that's an e-brake for all you Americans ) to the 60-series rear axle type. I will be utilising the components for this from my 1983 HJ60. Without the handbrake drum at the back of the T-case, do I still need to relocate the x-member further back or will it clear? If so, I'll probably enlist the help of someone more experienced in chassis chopping and welding practices!

Will the bellhousing currently on the H55F (from an HJ75) bolt right up to my 2H? I have heard of needing to modify the bellhousing slightly, but figured that if I use the bellhousing from the HJ75 I wouldn't have to do this.

And, how compatible are the wiring harnesses from the HJ75 transmission and my HJ47? I have just completely redone the wiring harness from the HJ75 - I would have checked the wiring diagram in my FSM, but the bloody dog chewed half of the book to bits. If it doesn't go, I'll modify the connector in my troopy to suit.

And finally, I want opinions on the state of the input shaft, namely the scoring on the surfaces in these photos:

 

[dmaddox]

Hello Kitty ..... for the win! Oh, and grats on the new tranny

 

[GLTHFJ60]

First off, beautiful!

Why do you have an oil return hose between the tranny and transfer if the seal between them is new?

I just got my H55 + split case installed in my 60 that I got from down under, and it had similar scouring on the input shaft. I threw it in without thinking about it and she's been fine.

 

[flaminbandit]

im unsure on a diesel but on my petrol the transfer JUST clears the rear crossmember

i fitted a exedy safari tuff clutch to my 45 when i did the 5 speed swap i dont wanna have to pull it out in a hurry the 4terrain gets some good reviews except i couldnt get a answer from them on who stocks there gear to buy one plus i got the exedy at wholesale cost price

and both the conections plugged straight in on my fj45


hope this helps

 

[dingbatt]

Firstly I must apologise as I cut that first post short, as I had to run urgently. So to continue from where I was at:

The scoring on the input shaft. Here's another photo, from around where the clutch fork/thrust bearing sits:



slightly worn, do you think it will be ok? Its worse on the underside.

Thanks heaps for the help, advice and knowledge dudes!!


Johnny,

this tranny is not new. Its not even been rebuilt! I figured I'd just clean it up, make it pretty and then put it in. It only looks new thanks to gallons of elbow grease, wire brushes, a ton of kerosene and a tin of POR-15 engine enamel . Hopefully it runs ok . So the seal between the tranny and t-case isn't new, and must be busted because the PO had some crappy homemade oil return hose that I replaced with the one you can see on there. Good to know that scoring wont be a major issue!

Flaminbandit,

Cheers man, that is helpful... At a guess I'd say the rear of the 2F engine in an FJ45 would be at the same place as the rear of a 2H in an HJ47, or at least the bellhousing would make up that difference...maybe... . But I'm willing to take a punt and figure that the tranny / t-case in an FJ45 and an HJ47 is in the same place relative to the chassis and x-members. So that's hearty news!
In the case that you are talking about, has the park brake been removed from the back of the t-case? And when you say JUST clears, what are we talking? millimetres?...
I suppose if worst comes to worst, I'll test fit it, and if that x-member needs chopping, a chopping it will get!
How strong is your left leg to operate that safari tuff clutch? Or am I being a wimp?!

Cheers,

Matt

 

[GLTHFJ60]

Matt, that explains why it's got that tube inbetween the two. Damn it looks good man, good work!

Other than hitting the scored section lightly with an emery cloth, I'd call it good. Mine was scored a little bit like that and it's fine.

What engine did that tranny / transfer come off of? I haven't seen that bellhousing before.

 

[dingbatt]

Matt, that explains why it's got that tube inbetween the two. Damn it looks good man, good work!

Other than hitting the scored section lightly with an emery cloth, I'd call it good. Mine was scored a little bit like that and it's fine.

What engine did that tranny / transfer come off of? I haven't seen that bellhousing before.

Came from an HJ75 (with 2H) - of which there are plenty around here in Aus.

 

[GLTHFJ60]

Came from an HJ75 (with 2H) - of which there are plenty around here in Aus.

Oh, wasn't sure what engines came in the 70 series cruisers. You should be golden to bolt that sucker in your 47 except for the crossmember, assuming the starter is in the same / close to the same place on both bellhousings.

 

[2manycruisers]

What clearance are you concerned with on the crossmember? My HJ45 has an h55f with the HJ60 crossmember and my front driveshaft and t-case flange clear fine. It was tough to get some of the driveshaft bolts on/off, but I managed.

What are you going to do for a park brake cable when you move your brake? I have an LX rear axle, but don't have a cable yet. FJ/HJ60 was too short. I was thinking maybe an HJ75 cable would work, but I'm in the US so I can't check that out.

You can't beat Toyota quality for parts, but I've generally had good luck with aftermarket clutches. And I agree with glthfj60 on the scoring, hit it with some emery cloth and call it good. Probably worst case is some chatter of the thrust bearing when you shift, but I doubt it.

 

[dingbatt]

What clearance are you concerned with on the crossmember? My HJ45 has an h55f with the HJ60 crossmember and my front driveshaft and t-case flange clear fine. It was tough to get some of the driveshaft bolts on/off, but I managed.

What are you going to do for a park brake cable when you move your brake? I have an LX rear axle, but don't have a cable yet. FJ/HJ60 was too short. I was thinking maybe an HJ75 cable would work, but I'm in the US so I can't check that out.

You can't beat Toyota quality for parts, but I've generally had good luck with aftermarket clutches. And I agree with glthfj60 on the scoring, hit it with some emery cloth and call it good. Probably worst case is some chatter of the thrust bearing when you shift, but I doubt it.

The crossmember that braces the chassis rails behind the transfer case - it has an arch in it which clears the driveshaft. That is the one I'm concerned about. I have been told it will require relocation further back, but also I have heard that it doesn't need moving...

Wouldn't an HJ60 crossmember be too wide? I'm assuming you're talking about the member which the tranny bolts up to at the bottom?...

There's a place just around the corner from work that can make a custom length handbrake cables. I'll probably end up using them. I'll be using the HJ60 backing plates, and I'll weld on the little brackets to my axle housing. I don't know if an HJ75 cable would be long enough - It would have to be close...

Cheers heaps .

Matt

 

[flaminbandit]

the clearance to the crossmember would be less than 5cm prolly 1-2cm in reality it scrapes past it while fitting it but once fitted its all good definatly makes it harder to fit it tho theres not much front-back room to get it all together


safari tuff clutch is quite heavy i wouldnt wanna drive it in peak hour traffic thats for sure

when you get the custom able made tell me how much cause i still havnt done my handbrake cable yet

 

[dingbatt]

flaminbandit,
Cheers man, that's helpful. So it'll be a squeeze, but she'll fit. Hopefully. When I do get it in, I'll measure up how long the lines will have to be and get a quote anjd let you know. But I dare say I'll be driving around for a while with no handbrake - but I'm rather used to that ... in my limited experience the transmission park brakes are pretty useless and a poor design.

Just picked up new bolts for the bellhousing to block, and a new rear main seal, as I am going to replace that while I'm there. I am pretty sure those small bolts aren't right, plus I only have 8 bolts; there are 10 holes in the flange of the bellhousing .... serves me right for not checking first. Back to the FSM.

Nonetheless, brand new genuine parts are exciting to get!

 

[flaminbandit]

also replace the pilot bearing while your there they dont come with most clutch kits gotta buy them seperatly (small bearing that goes in the crankshaft)

 

[RufusTheDufus]

Since you're in AU you might want to call around to find the correct 40 series plate and shifter so you don't have to cut up your floor pan. Those things are almost worth their weight in gold here in the states because they are so rare. Down there you might have much better luck finding one at a reasonable price at a wrecker. In my opinion it's worth the extra cash and effort to keep from butchering the floor pan.

 

[dingbatt]

Rufus,

Cheers for the suggestion, it is a good one! I had considered this and had a pretty lacklustre look around. I was kinda resigned to chopping the tranny hump up, but I may renew my search with vigor!

I bought a clutch kit through eBay, a 4terrain kit. Hopefully it will be arriving today. Toyota parts were out of stock for clutch kits, surprisingly. I think it must be due to the large number of aftermarket replacement kits available on the market, from cheap replacements (~$300) through to hard core heavy duty kits (~$650) - whereas a Toyota kit costs about $540.

Anyway, I am planning on doing the swap next weekend. I'll get Old Yella towed into my work's workshop and spend the weekend on it. I think I'll need plenty of time as I have not done anything like this before.

Cheers,

Matt

 

[2manycruisers]

Ah, the fixed crossmember. My HJ45 has a sbc 350 with Marks kit, so the tranny is close to the stock location (not sure if exactly there or not). I had to tilt the motor in the front mounts to get the tranny lined up. Once there and bolted up, it clears the rear x-member fine.

I'd agree with Rufus--look for an '83-84 doghouse cover so you don't have to re-make yours. Mine was a PITA. Good luck.

The crossmember that braces the chassis rails behind the transfer case - it has an arch in it which clears the driveshaft. That is the one I'm concerned about. I have been told it will require relocation further back, but also I have heard that it doesn't need moving...

Wouldn't an HJ60 crossmember be too wide? I'm assuming you're talking about the member which the tranny bolts up to at the bottom?...

There's a place just around the corner from work that can make a custom length handbrake cables. I'll probably end up using them. I'll be using the HJ60 backing plates, and I'll weld on the little brackets to my axle housing. I don't know if an HJ75 cable would be long enough - It would have to be close...

Cheers heaps .

Matt

 

[flaminbandit]

hey id be willing to swap trans covers mines been modded to suit a 60 series box
but ive since done a twinstick conversion on the transfercase and want to relocate the hole further forward


would be easier for me to mod a stock one rather than my modded one

 

[dingbatt]

hey id be willing to swap trans covers mines been modded to suit a 60 series box
but ive since done a twinstick conversion on the transfercase and want to relocate the hole further forward


would be easier for me to mod a stock one rather than my modded one

Sorry dude, I don't think I follow exactly what you're saying.... do you mean you want to swap toploaders or tranny humps? If I do end up getting a 40 series H55F toploader and using that, I'd send ya the old HJ75 one no worries.

Anyway, my clutch kit arrived yesterday, purrty:
View attachment 351906

Came in a sweet box too, that'll come in handy for parts in the future
View attachment 351907

So I pretty much have everything ready now, unless I do this toploader swap....

I have:
-Complete H55F with bellhousing & split case
-remade wiring harness (hopefully connectors are all compatible)
-Clutch cover plate
-Clutch disk
-Thrust bearing
-Pilot bearing
-Rear main seal


Anything missing?


When the transmission is in, I can measure up new driveshaft lengths and get them machined. Same with the park brake, I'll get the lengths measured up for that and get a price.

I also need to pick up a clutch alignment tool for the clutch install.

 

[dingbatt]

I don't think those attachments worked, here's the photos:

 

[flaminbandit]

i mean tranny humps ive got one modded to suit the 60 series box