Split case transfer upgrade - shifter problem (1 Viewer)

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I have just upgraded my BJ40 to split case transfer and matching four speed. Mine was a 4/80 model so have changed to 8/80 onwards.

My transfer shifter is fouling the transmission cover in the H4 and L4 positions.

As far as I know the transmission covers did not change from 79 onwards.

It’s possible I have mismatched the linkages/shifter between the two. Did these change when the split case came in 8/80?
 
@Living in the Past has posted the difference in shape of the transfer shifters, see which one you have versus what is needed.
 
The top one on the lug wrench is from a one piece transfer case. Next one down is from a split case four speed.
IMG_2810.JPG

Angle changed a little. Which shifter are you using? Possible to bend your current one forward. Because it's all metal can use heat to help bend it. The later two piece style you would have to worry about the rubber melting between the two pieces if it gets to hot.
 
Thank you very much. Really appreciate it.

I am using the 1st shifter and have the second one I could change to.

What is the third shifter from? My 83 HJ47 looks to have this type.
 
What is the third shifter from? My 83 HJ47 looks to have this type.

The third one is from a 83 BJ42 with a H55F five speed. I did search and see the BJ42 and BJ40 used a different shifters. Not sure which one is the second one in the picture. Same with the ones in the upper right. I have collected a number of different shifters for the transmission and transfer case over the years. Same with the boots for them.

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Interesting. I checked a 82 BJ42 and it has the second lever. This BJ42 is a split case/4 speed but it has the handbrake in the rear axle so they must have done this once the 5 speed came into production as an option.

My 83 HJ47 has the third lever. Now in Australia the HJ47 never had a 5 speed option. Perhaps they all changed to this third style shifter sometime in 83?
 
Interesting. I checked a 82 BJ42 and it has the second lever. This BJ42 is a split case/4 speed but it has the handbrake in the rear axle so they must have done this once the 5 speed came into production as an option.

My 83 HJ47 has the third lever. Now in Australia the HJ47 never had a 5 speed option. Perhaps they all changed to this third style shifter sometime in 83?


If your 83 HJ47 has the common H41 that middle lever would move the shifter up under the heater. The boss in the four speed case is in front of the bulge for the reverse gear. The H55F and late four speed with the dummy spacer on the back is on the reverse gear bulge. The angle on the Middle shifter is to try and get the lever closer to the placement on the four speed.

Upper left is from 82 FJ40 H42. Upper right is from a 83 BJ42 with a H55F. Bottom right is from a 84 HJ47 with a H41 with hand brake on the transfer case.

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The next lever down is from a FJ60 with H42 with the dummy spacer on the back. This correct for 60/62 series being changed to a H55F. This are NLA and so popular aftermarket one are being made.
 
Thank you. Would you have a photo that showed the right hand side of those covers? They are cut off in the photo.

My 47 has the standard H41. I will get a photo of it.

I am thinking my BJ40 now needs the cover plate with the wider transfer home to engage L4.
 
It turns out I should have looked at my own vehicles harder.

My 83 HJ47 has a different transmission cover plate to the 80 BJ40. It has a hump, different (larger) gearbox rubber boot and the transfer shifter cut out goes further to the right. It also has the 2nd shifter stick after all.

Will I need this later model cover plate for my split case conversion?

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It turns out I should have looked at my own vehicles harder.

My 83 HJ47 has a different transmission cover plate to the 80 BJ40. It has a hump, different (larger) gearbox rubber boot and the transfer shifter cut out goes further to the right. It also has the 2nd shifter stick after all.

Will I need this later model cover plate for my split case conversion?

View attachment 3207056

View attachment 3207057


Unless you are switching to a H55F in your BJ40 there should be no clearance issues. The aluminum top cover is taller on the H55F. While it wouldn't bolt on your 83 HJ47 the /79- 9/82 cover would have no clearance problem. 10/82 the tubs changed in the hump on all 40 series while it had four speed or a five speed. For the most part the BJ42 and FJ40 switched to a five speed 10/82 in Australia. The HJ47 and FJ45 never had a five speed option. Even though a five speed wasn't an option the hump changed in the long wheel base just like the short and mid wheel base 40 series. If I had a 83/84 HJ47 would already have a H55F installed. The Australian market 8/80+ BJ42 and FJ40 are FF rear axle with the hand brake. Also possible to convert the current rear axle to hand brake.

I have probably explored what it would to take to put a H55F into a 1/79-9/82 40 series than most.
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The middle.picture was taken with a reverse screen on a old phone to get a better shot of the gap at the front. Picture is a mirror image and backwards. Does highlight the gap at the from. For reference the tub is a 3/82 FJ40. Cover is 3/83 BJ42 with a H55F.
 
This is an H55F in a mates 2/82 HJ47.

So to confirm you don’t need these mods on a 10/82 onwards?

5465DFAD-7214-4CE4-8F79-C0D21223B008.jpeg
 
This is an H55F in a mates 2/82 HJ47.

So to confirm you don’t need these mods on a 10/82 onwards?

View attachment 3207619

Correct no mods would be needed to the hump. But that is also using the correct 40 series H55F top cover which the one pictures is not.

Here is a H55F from a FJ73 which the same as the 60 series
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This is one from a BJ42 which is the cover used on all BJ42s and FJ40s with the H55F.
IMG_20200219_141020196.jpg

The torque tube behind the transfer case is in the same location on all 40 series 1/79 and later. Would require some mods to make it work with a hand brake on the transfer case when running a H55F. Toyota decided to only run a four speed on the FJ45 and HJ47 instead routing a long cable to the back axle.
 
The top one on the lug wrench is from a one piece transfer case. Next one down is from a split case four speed.
View attachment 3205594
Angle changed a little. Which shifter are you using? Possible to bend your current one forward. Because it's all metal can use heat to help bend it. The later two piece style you would have to worry about the rubber melting between the two pieces if it gets to hot.

I changed to correct shifter and this has moved the shifter forward and provided more clearance in the 4WD position.

I still don’t have enough clearance to engage Low Range.

I have adjusted the linkage with the ball joint that actuated the H/N/L lever however it doesn’t provide adjustment.

This linkage must have changed when the early tub (pre-10/82) had the split case transfer?
 
The drawing in the parts catalogue actually shows a different shifter with three bends:

DC19AE73-794C-4FF3-9143-BFBDD7CEA927.png
 
The drawing in the parts catalogue actually shows a different shifter with three bends:

View attachment 3216504


Can't go by those diagrams. Looked up the transfer case guide for the four prior to 8/80. Pictured on Amayama was the three speed style that requires two bolts on the transmission cover. Then looked at the 8/80+ for four speed on the 40 series. Pictured is the style actually used. Part number prior and after is the same. Look up on Amayama the transfer case shifter for the 40 series H55F. Shows the same diagram you just posted. That shifter pivots off the reverse gear housing on the transmission case and bends forward.

Would look at the shaft the moves the lever for high low on the transfer case. That may need to be adjusted for that to have the high low shift a little quicker. I do show that rod had a change from the one piece transfer case and the split transfer case.
 
It’s not the guide. It’s the lever hitting the body of the vehicle. I have adjusted the ball joint linkage as far as it will go. It has the be the wrong lever. It would work in late tub but not my 4/80.
 

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