Old Yella gets a 5th gear!

[dingbatt]

Aaaaahh.... That makes a whole lotta sense. Forgive my feeble mind. Yeah man, that'd be sweet. I'm gonna call a couple of places about a J40 toploader, but if not successful, I'm definitely up for a swap man.

Cheers,

Matt

 

[dingbatt]

It has begun

I didn't have any luck finding a J4* series toploader, so tranny hump modification it is!

So, flaminbandit, wanna swap?



Pulling out the H41 today. Photos will be forthcoming.

In the meantime, here's a couple of photos of the floorpans - my next project will be to clean these up, cut out that rust on the driver's side and replace it, lay down some coats of POR-15, then cover with some proper thermal / acoustic insulation. Surely that foam is not OEM? Its brittle as fxxx! Looks like the PO also had a go of replacing part of the passenger's side floor with some thick plate.

 

[dingbatt]

So I finally got the H41 out ... bit of a mission when done by yourself! I'm definitely gonna get someone to help with the H55F install. I think that'd be a bridge too far on my lonesome.

Here's the old tranny and transfer:


And here's the offending linkage that has fallen down into the transfer case that immobilised the poor old girl months ago.:

 

[dingbatt]

I'm certain from what I ordered that this is the right clutch kit, but the clutch discs look quite different:



The old one (top one on the photo) has a thicker mid section and quite a different spring setup, also the older one is larger in diameter.

I'm sure the new one will work fine, but I just wanted to check that these sorts of differences are normal for different clutch manufacturers.

Do you guys reckon I have anything to worry about?

Cheers,

Matt

 

[dingbatt]

It's in!

So I finally got the transmission in. Luckily I had a mate help me this time, it was a fiddly thing to get into place, but we managed ok. Fastening the top two clutch housing bolts was probably the hardest part. Those little bitches took my ages to tweak.

Here's some phototos:

new clutch:


From underneath:


From inside:

 

[dingbatt]

I am concerned about how the tranny support is currently sitting, though. It was very fiddly to get back into place. You can see that the rubber mountings have been pushed right over, especially on the right hand side - so much so that I could not fit a ring spanner over one of the bolt heads. It seems like they don't quite line up properly. I'm not sure if this will settle with time or not. I find it bizarre that it is not aligning left / right correctly, I thought if anything the alignment issue would be front to back ....




Has anyone had this issue before? Any suggestions on how to remedy this?

It also looks like I'll have to bend the gear shifter straighter, as it currently goes waaaay too far back in 2nd, 4th and rvse, and interferes with the centre console and driver's seat. The transfer shifter also interferes on the side of the tranny hump, as you can see in the photo below. I'm not sure I can fix this by bending it, as the bend whould have to be very close to the pivot point of the lever. I am loath to cut a chunk out of the body here as well. Any suggestions? ... will the transfer shifter from my H41 work? That may be easier to bend....



I also got a couple of quotes to shorten the rear and lengthen the front driveshafts ... it doesn't look like I'll get much change out of $500 - does that seem a bit expensive to you guys or what? I've never had this sort of work done before so I really don't know what to expect ....

Cheers guys,

Matt

 

[herbs]

Looks good, I think you can bend that transfer stick, just take it out, put it in a vice then get happy with the oxy. Same with the gearstick. I might have a squizz at the sticks in my H55 equpped bj 42 come tomorrow.

Edit: Or can you cut the transfer stick off at the pivot point, rotate it around and reweld it back on?

 

[dingbatt]

...I might have a squizz at the sticks in my H55 equpped bj 42 come tomorrow...

If you could man that would be great - was your bj42 factory equipped with an H55F though? If so, the gear shifter will have to follow a different line as it comes out of a different place ontop of the tranny. The design of the transfer shifter should suit regardless though, I'd imagine...

Cheers,

Matt

 

[herbs]

Haven't got around to it yet, but yeah my 42 has the factory 5 speed, but I think the transfer linkages should be similar to the 75 series, but with a different stick. You don't want to have that lever sticking over too far in 4 low, good way to hurt your left shin.

 

[dingbatt]

Haven't got around to it yet, but yeah my 42 has the factory 5 speed, but I think the transfer linkages should be similar to the 75 series, but with a different stick. You don't want to have that lever sticking over too far in 4 low, good way to hurt your left shin.

Indeed!....

Cheers man.

 

[herbs]

Had a look and my transfer stick has 2 bends, the lower one brings it forward and a bit to the left, the higher bend puts the upper part of the stick (that you hold onto) into the standard 40 series position.

Quick pic:


Hope it helps.

 

[dingbatt]

Had a look and my transfer stick has 2 bends, the lower one brings it forward and a bit to the left, the higher bend puts the upper part of the stick (that you hold onto) into the standard 40 series position.

Hope it helps.

Yeah that makes sense, I'll try and follow that sort of curve.

You're a champion mate, cheers for the help!

 

[dingbatt]

Help!

Ok, I got the driveshafts back. They look brand new .



However, I have a problem .

The front driveshaft does not appear have sufficient clearance past the tranny support member to allow for drop of the front suspension.
Here's a shot of how close the driveshaft runs to the tranny support member:



I unbolted the front driveshaft from the front flange and left the other end bolted to the transfer and let it rest on the support member to see how much downward suspension travel it would have before the driveshaft hits the support member. Here is what it looks like:



Not much hey?

What should I do? Modify the Support member? Do I need to use a different support member from a factory H55 equipped landcruiser???
I'm also worried that it may related to the issue I had with the tranny alignment - see post #26.
Has anyone who has done this conversion encontered this problem before? Or have I done something wrong?

Any help would be much appreciated.

Cheers,

Matt

 

[cruiserbrett]

looks like you will have a 2wd hj47 for a bit.

check calicruiser's h55f/toybox thread in the fj60 section for a nice mod to the crossmember to deal with this issue. should be about the first page

 

[2manycruisers]

Looking good. $500 for the driveshaft mods seems expensive, but maybe not in AU $$. Shortening the rear should be less than AU$100, re-tubing the front may be expensive. I haven't had that work done in a while, so I'm probably not a good judge. Interesting to see the 75-series tranny/xfer in there. I used a 60-series in my troopy and had no clearance problems with either shifter.

Bummer about the xmember clearance, definitely a mod to the xmember is the best fix. I'll have to look at mine, I don't remember it being so close. But I also haven't driven it since I installed it 9 months ago.

 

[Chamba]

Matt,

Turn your drive shaft around: the slip yoke goes toward the transfer case. You will have plenty of space then.

Cheers,

Josh

 

[herbs]

Yep, the man speaks the truth, slip yoke end goes up to the transfer.

 

[dingbatt]

Sorry, I have been busy all weekend with other errands, and haven't had the chance to jump on the net until now.

First up, thanks heaps for the replies guys. This driveshaft clearance thing has been on my mind all weekend!

looks like you will have a 2wd hj47 for a bit.

check calicruiser's h55f/toybox thread in the fj60 section for a nice mod to the crossmember to deal with this issue. should be about the first page

Cheers for the heads up brett, that is some fine fab work that guy did there - I'm not sure mine would be up to that sort of standard! Good reference though. Cheers.

Looking good. $500 for the driveshaft mods seems expensive, but maybe not in AU $$. Shortening the rear should be less than AU$100, re-tubing the front may be expensive. I haven't had that work done in a while, so I'm probably not a good judge. Interesting to see the 75-series tranny/xfer in there. I used a 60-series in my troopy and had no clearance problems with either shifter.

Bummer about the xmember clearance, definitely a mod to the xmember is the best fix. I'll have to look at mine, I don't remember it being so close. But I also haven't driven it since I installed it 9 months ago.

The total price ended up being $430 - most of that was for retubing the front driveshaft. That said, i think shortening the rear cost about $130. Anyway, I was quite happy with their standard of service - they cleaned, painted and greased them nicely and fixed up a loose dust boot on their own volition.

Matt,

Turn your drive shaft around: the slip yoke goes toward the transfer case. You will have plenty of space then.

Cheers,

Josh

Yep, the man speaks the truth, slip yoke end goes up to the transfer.

Josh / herbs,

Doing this had occurred to me, but I just wasn't sure if it would be ok.... I don't see how there would be any problem with turning the driveshaft around, apart from maybe changing the torque stress distribution across the driveshaft - but hey, I'm no mechanical engineer, that's for sure. In fact, it would actually tuck the slip yoke safely up and away from dangerously nasty rocks and such. I'll swing it around today and see how she fits, and post some pics of course.

Would there be any disadvantages associated with running the driveshaft this way around?

OR did you mean that the slip yoke end is usually at the transfer case? Because I've never seen it that way around. Just curious.

Cheers again dudes,

Matt

 

[herbs]

The front driveshaft on my bj 42 is arranged this way, so Toyota thought that it was a pretty good idea.

 

[dingbatt]

The front driveshaft on my bj 42 is arranged this way, so Toyota thought that it was a pretty good idea.

Sweet! We all know Toyota know how to engineer things extremely well - otherwise this site would not exist in all its glory! So I'm willing to trust them - and an extremely simple solution to boot .

Cheers man