Putting a Marlin Toybox in a 74 FJ40

[waskillywabbit]

Here is what I know (I'll update it as I know more and add some pictures this weekend as I only looked at the FJ40 in the dark for about 10 minutes at my shop)

Solid lifted and locked 74 FJ40 with what appears to be stock motor, 4 spd tranny and tcase

Marlin Toybox with the following engravings:
MC24 H42/H55 on one side and MC21 Toybox on the other

Scheduled work to be done starting 2nd weekend in November so I'm doing my homework now.

I talked with Woody today and he directed me to this section of the forum and to several threads.
Thanks Woody!

From my reading it seems there is no standard one size fits all write-up for doing this and that it will be a lot of custom fab work. Anyway, I've familiar with minitruck stuff, so I'm not a newb, but this will be the first time for this sort of thing on an FJ40.

Rather than cloud the water with my preconceived notions and perhaps wrong assumptions, please share with me any insight, links, pics etc as to what I am going to have to do to get this Toybox in this 40.

Thanks for your advice.

I will be sure to update the thread as we progress.

 

[76FJ40]

Check John Smith's article in the transfer case section of Tech Links to get started.


http://users.starpower.net/johnsmith/

 

[waskillywabbit]

Excellent tech article I had not found in my searching. Going to have to read that one several times through.

Thank you.

 

[canadian bum]

Has anyone ever broken one of these in a Cruiser? Just doing some homework before I bolt one behind my diesels. Nothing is unbreakable just wondering if they stand up to big torque?

 

[Slowerthanu]

Has anyone ever broken one of these in a Cruiser? Just doing some homework before I bolt one behind my diesels. Nothing is unbreakable just wondering if they stand up to big torque?

Nothing is indestructible but I have not heard of any grenading. I bet you would break something else before this.

 

[Jerry D.]

You may want to take a look here: Fl Cruiser.... What did ya find in the Toy Box?

He has a diesel in a FJ60, some pictures of the damage also...


Jerry D.

 

[mwalls54]

I just did this in my 74. Here is the thread.

https://forum.ih8mud.com/40-55-series-tech/294748-started-bring-my-74-fj40-back-life.html

 

[waskillywabbit]

Hear are the pics of the important stuff:

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[waskillywabbit]

11.

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19.

 

[76FJ40]

Has anyone ever broken one of these in a Cruiser? Just doing some homework before I bolt one behind my diesels. Nothing is unbreakable just wondering if they stand up to big torque?

Just think of your LC xfr case as a driveline fuse, it will go before the Toybox - don't ask me how I know.

 

[Johnpenner]

Where did you get that Marlin box, They dont make those anymore...
From what I understand you need the newer '79 & up split case & tranny that goes w/ it.

 

[waskillywabbit]

Customer said he bought it over two years ago, so it is possible it is a not made any longer.

I didn't see it on Marlin's website as of tonight either.

 

[Johnpenner]

would be nice to find one...
anyone?
anyone?
Beuller?

 

[ColoCruiserJeff]

I have been looking to do this install for quite some time - seeing ToyBox'd cruisers at CM10 it was amazing the difference in performance over the stock set-up.

I called Marlin....and since his "Land Cruiser" guy wasn't in - they were not of much help. Couldn't figure out what I was trying to tell the guy....so I'm guessing I have to call back when he's back in.

 

[ColoCruiserJeff]

So....I called back to Marlin's shop...actually got ahold of Adeberry (sp) at Marlin - and he no longer sells the MC21 unit....as they went with the finer-splined output shaft that works with the split-case only. (19 or 21 spline I think)

He said it'll work with an H41,H42,H55 -just specify which one he said. For what it's worth, the part number is: MC-H42-SC470

It'll run about $1900 for the toybox unit!!! And they're about 2-3 weeks out for production.

Wondering how much it costs to modify the driveshafts to accomodate for the added length - maybe even have to go with a double cardan CV joint - probably stronger??

 

[tornadoalleycruiser]

you have options.. If you have the older 10spline toybox and have the corresponding tailshaft for an h42 then your set. your trans output will either be 10 or 19spline from my recollection. What you probably have right now is a 16 spline output shaft.. you need a 10.. to mimic the SM420 or 3spd Trans.

I might have a 10 spline toybox tailshaft for an H42 lying around if you don't have one in the pile.

Output you'll need to count splines..
Grind a spot for the shift rail on the toybox in your tcase.

you'll need to flip the rear springs with an inline 6 and a 4spd with a toybox. most people on here will tell you there is no way it will fit.. it does work. I ran a cv joint out of a minitruck for the rear driveshaft.

I personally wouldn't run that tcase behind a toybox but whatever your customer wants will work.

Count splines on output of toybox and report back.

 

[Mace]

Yeah, I am not sure I'd run a stock 3 speed or 4 speed tcase behind a toybox without every single extra support plate produced. There is just too much stress going through that little tcase.

I am running dual mini tcases/SM420/Turbo 2F. I REALLY like the gearing options. But stupid low (200:1) is barely used even with 40's and 1 tons in a crawler.

 

[Cruiserdrew]

If you buy the Toybox, it comes with an H42 mainshaft with a 10 spline output, so you swap that before you install the Toybox.

There are 2 Toybox inputs-either 10 spline or 19 spline, but the 19 spline is only used with the H55 as far as I know, and the one in the pics here has 10. I am nearly certain Marlin will have brand new H42 main shafts available with the 10 spline output needed.

How many splines on the output shaft of that Toybox? If 16, you're golden. If it's 19 you will need a split case. If 10, I think you can swap a 10 spline input into your transfer case from a 73. (I actually do not know the input spline count on a 74 case, but I think it is 16. That's the "transition year".)

What's the budget here? You are going to end up rebuilding both the transmission and a t-case, possibly sourcing a new t-case, modding driveshafts, twin stick shifters etc. All doable but the $$ adds up pretty quick.

Might be cheaper and easier to just put an Orion in the 40 as is. And then you have no driveshaft, shifter or mounting mods to think about.


If I were rebuilding my 40 again, I would use SM465/Orion and be done with it.



And let me agree with others here that a 1 piece t-case behind a Toybox is asking for problems. You might get away with it, but it's not a strong t-case for all that torque.

 

[Superstrength08]

If you buy the Toybox, it comes with an H42 mainshaft with a 10 spline output, so you swap that before you install the Toybox.

There are 2 Toybox inputs-either 10 spline or 19 spline, but the 19 spline is only used with the H55 as far as I know, and the one in the pics here has 10. I am nearly certain Marlin will have brand new H42 main shafts available with the 10 spline output needed.

How many splines on the output shaft of that Toybox? If 16, you're golden. If it's 19 you will need a split case. If 10, I think you can swap a 10 spline input into your transfer case from a 73. (I actually do not know the input spline count on a 74 case, but I think it is 16. That's the "transition year".)

What's the budget here? You are going to end up rebuilding both the transmission and a t-case, possibly sourcing a new t-case, modding driveshafts, twin stick shifters etc. All doable but the $$ adds up pretty quick.

Might be cheaper and easier to just put an Orion in the 40 as is. And then you have no driveshaft, shifter or mounting mods to think about.


If I were rebuilding my 40 again, I would use SM465/Orion and be done with it.



And let me agree with others here that a 1 piece t-case behind a Toybox is asking for problems. You might get away with it, but it's not a strong t-case for all that torque.

The toybox is ten spline on both sides.

I do not really know what my budget is so custom drive lines and stuff doesn't really matter as long as it works in the end. I just want it to be a fun toy and somewhat unique haha.

I am just going to leave the stock t-case in and if i have problems out of it I will replace it once it dies. is there way to brace the stock one piece t-case so that it will last a little bit longer. I am not planning on running huge tires yet so I'm hoping that it will not be too much stress for the t-case...

I got this box about two years ago as a Christmas gift and have yet to install it due to just a simple lack of attention to the project once i started college. Now i just want to put it in and drive.

 

[Superstrength08]

also... does anyone know where i can find a strong clutch to put in when we do the install. the one in there now doesn't really hold well so i just want to replace it now so i do not have to go in later and deal with it.