Out with the Semi-Old A440-In with the H55

[ChuckB]

Guy I'm jumping over from ExPo.

I hope I didn't scare you and maybe someone can answer it here so I can put some solid facts on the table.

Does the Smog Police in CA have an issue with a swap like this?

 

[Cruiserdrew]

Guy I'm jumping over from ExPo.

I hope I didn't scare you and maybe someone can answer it here so I can put some solid facts on the table.

Does the Smog Police in CA have an issue with a swap like this?

Potentially, yes.

However, they would have to notice, which is not that likely.

I don't think the 3FE was certified with a manual, and so they might want to see an autobox in there. Emissions will be the same either way, since the engine computer does not use transmission inputs for anything. Don't ask for things to make sense. It's California smog after all.

 

[pismo62]

ChuckB--The shop that does my smog tests, is the guy who helps with my tech questions. he doesn't see a problem with it. But thats not a conclusive answer. I would defer to what Cruiserdrew says, he has much more knowledge is this area.

I'm sticking with the don't ask don't tell theory..

Hope that helps.

 

[ChuckB]

I'm sticking with the don't ask don't tell theory..

Hope that helps.

Keep us posted the next time you get it smogged. Good luck with the rest of the swap!!

 

[qldunipolo]

I did the conversion on my 89 two years ago October next. Had it smogged last week for the first time since at our usual test only shop in Costa Mesa. The tech loved the change over. The print out sent to the DMV indicated that the truck is a manual transmission. It easily passed. No other questions or comments.

We did the crossmember as mentioned above. Supported the transmission in place with a jack. Attached the corssmember and mounts to the transmission. Used steel angle drilled and bolted to the crossmember and then welded the angle to the frame.

Its been a great change. The truck is a lot more enjoyable to drive, more responsive to the throttle, really uses the 3FE's power well. My favorite ride.

Anyone have any suggestions as to what to do with the old A440F? I've had it in the garage for 18 months now and its gotta go.

Regards,

MM

 

[ChuckB]

That's great news, thanks!!

 

[Aseif007]

I put a 3F-E and H55 into an 87' FJ-60 and the referee failled my conversion visually (even though I passed the sniffer and evrything smog equipment wise was there). Then I contested it and the second time around the referee found some literature that showed an 87' FJ-62 as having the 5-speed option. I said nothing and the conversion went through and I got my sticker. Initially they wanted the A440F to come with the 3FE. Just my experiences with the 3FE and a CA conversion.

 

[ChuckB]

Interesting...

 

[pismo62]

Had some time to work on the project today.

I was able to finish up the tranny hump plates. A small one to cover the automatic opening, and the large one. For the large one, I had to take my existing cover and the 84 I got and combine them to make the new one. The 84 had the TC lever hole covered and welded, Why, No idea. Rather than try to cut it out, I just cut the two and put them together. I think it turned out pretty good.

Next was the crossmember. i waiting on a couple small part for the TC so I decided to mount up the H55 with less weight and make sure the bell housing and tranny lined up. Also, to mount the crossmember with out the TC in the way. I went back and forth on the idea of welding it in or bolting it. Mainly because, (when welded) to remove the crossmember when attched to the L-brackets you have to lift the crossmember up. so you have to make sure that you have enough room to jack up the engine/tranny to clear the attachment bolts. If it is bolted to the frame you undo the bolts and let it all drop down. I found there was enough room to lift the crossmember out so I tacked it in, then will finish welding it with the tranny and bellhousing out. That way I wont be hitting my head so often.

I ran into a snag with the exhaust. My catalytic converter was right in the way of the crossmember mount. So i had to cut it out and will have to re-route it.

I'm wondering how others have mounted up the clutch lines, It seems like snaking them through would be tough.

Thanks, Guy

 

[pismo62]

I was taking the transfer case apart today and mounting it to the H55. When i was taking it apart I noticed there was no rear thrust washer, Is that normal? (Note--I had the TC rebuilt 2 years ago by a local shop, now out of buisiness) In the manual it shows one being there and has certain tolerances. I also noticed that on the front of the idler gear on the oil reciever plate there are marks from the imput gear. Is this how they usally look or is this because there is no rear thrust washer to keep the idler gear centered? I ordered a new washer but it sets me back a couple more days.

Also, while I was welding up the L brackets for the crossmember I nicked the brake line. One more thing to fix.

 

[Cruiserdrew]

You have to have the thrust washer. look in the bottom of the case and see if it slipped during assembly.


BTW-It is easier to install the t-case to the transmission and then intstall the whole thing as a unit.

 

[pismo62]

Thanks Drew--I was thinking the same. I was hoping it slipped down, but it didn't. I don't think the guy who rebuilt it put it back in there.

PS--I put the tranny in to do the fitting for the crossmember, plus I was waiting on parts. I also thought it would be easier to try it in without the heavy TC on there.

 

[Rusty Pig]

Just curious on why you thought the clutch master cylinder didn't line up with the holes on the firewall? Does it have to do with early (prior to 85) VS later clutch master cylinder?

 

[pismo62]

Rusty pig--From what i gather toyota changed the bolt pattern somewhere in 84-85. I just happen to be using a early 84 clutch master cylinder and the firewall bolt pattern in mine is for the 85 and up. Thats why i had to redrill the holes. Not really a big deal.

 

[Rusty Pig]

Good stuff, thanks for the reply. I must check this thread three times a day, starting this conversion myself so your write-up is perfect!

 

[pismo62]

Side Note--Did anyone notice the input gear on my TC is the Macnamara gear? I put that on when I had the TC rebuilt. I'm going to leave it on there for the 5 speed.

Stalled--Waiting for the thrust washer--and heading out with my boys on a small backpack trip.

 

[EOE_overland]

Good stuff, thanks for the reply. I must check this thread three times a day, starting this conversion myself so your write-up is perfect!

X2! Great pictures too! I've got all the parts to do my swap now, and the pictures you took so far are helping to get rid of the "pre-swap jitters." Keep up the good work!

 

[pismo62]

Back in Town and back to my project:

I got the thrust bearing and put it on and reassembled the TC. Then that night I started reviewing previous post and relized I didn't put on the 5th gear oiler. I e-mailed Cruiserdrew and asked if it was really needed..Affirmative.

I really like to take things apart 2 or 3 times to make sure I know it backward and forward.

!!!!! DON'T FORGET TO PUT ON THE 5TH GEAR OILER WHEN REBUILDING THE TRANSFERCASE FOR A 5 SPEED !!!!!


So I had to wait for a new seal after I tore it down again.

The TC is all put back together again, except for one switch that has to be repaired and the vacume actuator for the 4wd, I'm going to wait until the tranny is in place so I don't inadvertantly break it off during the mounting process. Also, I put on the shifting fork and throw out bearing. Brake line repaired. Almost ready to put in.


I need to mount the flywheel and clutch.


I measured the differences in bellhousing to TC. The a440 from bellhousing to TC is 26 3/4, The H55 is 21 3/4. 5 1/2 inch difference.

I'm trying to get the tranny in this weekend.

Pictures are Oiler, Oiler in place on front of TC, and reassebled TC

 

[brokenparts]

love that cruiser man....

 

[Spook50]

So from what it appears, that oiler just catches what the gears splash up and directs it to the 5th gear?

BTW, any pics of the slave cylinder and release fork setup, and/or the line routing from the master cylinder? Just curious, for the sake of my reference.