Split Case Rebuild

[Cruiserdrew]

I will have many questions here and this is the first. I want to know about rebuilding a split case transfer. I have an '84 FJ60 that is running and shifting fine, but of course, that isn't enough...

I purchased an '86 split case transfer from a guy I trust and have purchased numerous used parts. The case is out of a running 60 with 150k miles. I believe it has the 38mm idler shaft. I will be buying an H55f transmission from Cruiserdan, then rebuilding the transfer and mating it to the H55f and installing in my FJ60. I have never rebuilt a transfer case before.
-Can a home mechanic do this without a lot of special tools?
-Where can I get a rebuild "kit" Toyota doesn't have one.
-Can I use the output flages from my existing '84 T-case? I want to stick with my existing flange pattern.
-Do I need the tranny first, and rebuild attached to the tranny?
-Anyone used the aussie low range gear sets?

Thanks for any and all responses.

 

[dd113]

You can do it. Get a factory manual first. The hi/low gear set need to be pressed on/off. any machine shop can do it. Rebuild kits are everywhere. Spend around $175 for a full kit. Try Cruiseroutfitters, me or TPI. You can do all the work except assembly without the tranny. It is not very hard but you have a lot of parts to deal with.

 

[60wag]

I was interested in the Aussie low range kits but the two common comments that turned me off were that they are noisy (gear whine) compared to OE gears and the cost. I think that with an H55, 4.11 diffs should be optimal, maybe 4.56 if you really want to crawl, with 33" tires.

 

[HZJ60 Guy]

The trouble (in my opinion) with the low range kits for split cases is that the HIGH range is effected too. If you put in a 3.0 gear set you'll have a reduction in your high range by 8% too. I dont like that. Marlin has been talking about a toy box for the H55 soon, but it has been a while.

http://www.marks4wd.com/lc-extra-low-tc-gears.htm

Marks also has a 3.0 ADD ON BOX that leaves your high range intact.


TB

 

[Mike S]

Good move, Andrew!

Mike S

 

[Cruiserdrew]

I have another question. Will I need a new crossmember? I have heard the H55f caan use the original one, but CDan says the part #'s are different. I'm asking now because I want it all ready to go so all I really need to do is get drive shafts modified and have minimal down time.

Additional info: The donor truck is a 5/86 so it does have the 38mm idler, and requires the later rebuild kit.

Thanks David and others. I have the factory manual from '84 (strangely it covers the 5speed and t-case) and the rebuild doesn't look too bad, but likely harder in person.

 

[hj60]

In 84, the diesels may have already come with the H-55F.

X-fer cases are easy to rebuild. tops.
With a split housing, even easier. Trying to rebuild a one-piece-housing
x-fer seems like it's alot like gynecology.

 

[HZJ60 Guy]

I think all the Canuck diesels came with H55's didnt they?

TB