toybox assembly and install (1 Viewer)

[nailed]

I just got finished the assembly and install of a toybox for my 83 FJ 60. It thas the stock 4 speed. I built twin stick linkage and a crossmember. Marlin doesn't send instructions with there parts, I thought I would share some of the issues and questions that I had. The tranny was shipped to Marlin for dissasembly and install of the output shaft. They also machined the doner case for 4.7 gears. The best advise I can give is dry fit everything once and take your time.

 

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With 4.7 gears the shift fork hits the gear when shifted into low, it will lock up in low with out some clearance modifacation???? The keyway is weld on the side as shown the other shift rod is removed. The threaded holes at the top of the toybox case need to be drilled out for studs to slide threw from one of the adaptor plates.

 

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This bearing is used from the doner case, it started life on the mainshaft of the mini truck, you will want to use the spacer and ball that holds the spacer from spinning. I was able to remove it with a large bearing puller. I then pressed it on the shaft. I think it could have been done by cooling the shaft and taping in on. The snap ring is really fun to get in there. Its held in with 3 allen bolts that should be included

 

[nailed]

I had to call Marlin twice about questions, they were more than helpfull and spent all the time I needed on the phone. Shipped quickly an Dave is a super nice guy. The retainer allens were missing, also I had to drill out for the studs pictured earlier and grind the case for clearance so the medium sized allen would sit flat. Not a big deal but made me scratch my head a while trying to figure al this out. The last pic is the flat spot for the allen, bad pic. All assembled and moving to the split case.

 

[nailed]

You have to remove some aluminum to get the cases to tighten. More roto zip work. The seal that rides on the gear should be replaced as there known to leak into the toybox. I had not passed this point in my dry fitting and later discovered I was missing spacers for correct gear alinement. Again they shipped fast and threw in some shift knobs for my troubles. I got the spacers Tuesday before Thanksgiving.

 

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Correct gear alinement and ready for assembly. The splitcase gears are huge next to the mini truck stuff. These things are built tuff,

 

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The case in designed for preload on the rear output bearing adjusted by gasket thickness. I used the caution when tightning the bolts around the output shaft to make sure it went down straight and didn't load the bearing funny. After torquing them down the preload felt good. I don't have a spring tester but am familuar with bearing load and it wasn't loose. Its safe to run with the original gasket. If it was time for rebuild this would require more effort to get right. I didn't torque down the main shaft nut to 94 ft lbs untill the cases were in the truck, I have a home made tool that uses the floor to hold the drive line flang.

Assembled and starting shift linkage.

 

[nailed]

The linkage and cross member took me something like 1 million hours to build. I used some of the stuff that I have read and made up my own plan. The linkage turned out good with lots of fitting, I had to move the attachment point for the high low shift rod because of too much throw, the shift lever would hit the dash and also the shift boot would not flex enough.

 

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linkage

 

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crossmember and skid

 

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Finished member using both mounts. It hangs down a little, about 3" below the frame. A better design could have more clearance but it is flush with the bottom of the split case now and I like the protection it provides. I know there is alot of talk about how many mounting points you shoud have or not have, I was going to use this with the stock crossmember modified to work around the driveline but changed my mind and cut it up for the front mount. Its plenty strong, I was careful to keep weight on the tranny mount to spread the loads. Any comments on this??? The tubeing is SCH 80 1" and the main is 2x4 3/16 wall.

 

[samibattlemaiden]

i love and hate these rite ups cause they make me not wanna put my tranny back in but, in stead spend a lotta money i don't have right now and do this amazingness then put it back in


drooool

 

[nailed]

So its all up in the cruiser now, I have moved on to the front end to finish welding and start painting. I hope to be done with the running gear except engine swap this winter. This being my first build I would have never guesses that there was so much time into this stuff. I could have build 3 homes with all the hours that are in this thing, although its very rewarding to look back and see what you have done. Marlin is the man, I am impressed with amount of stuff they did to make a toybox. Then think about all the different models and there little differences. Quite amazing really.

 

[cuteo100]

Thanks for the write-up and nice work! I am on the fence about putting one in. If I am not mistaken, stock final crawl ratio is 30:1 for an 84 cruiser and now it is about 213:1 more or less!

However, reading earlier posts over here and over at pirate4x4 there is a disturbing pattern: everyone is having issues installing these because of missing parts, missing instructions, and some modifications required. Marlin is leaving it all for the customer to figure it out on his own, or he just loves to spend time on the phone with each and every customer every time? You wasted a lot of time figuring it out but seems very sympathetic to Marlin so it says a lot about his excellent product. At the very least, I want installation instructions for my kit!

 

[baxter650]

Thanks for sharing, this is still high on my list of things to do.

 

[nailed]

Not having instructions was difficult but I am not in a hurry to finish so it wasn't a big deal. When it was really slow after the new year they sold me there last existing "shaft". It was saved for possible warranty but there hasn't been a issue. They were expecting the new shipment so they sold it to me. I was ready to do this then but after shipping the tranny and there machine work it was spring when I got it back. Spring time is bad with the kids in baseball and other commitments. I haven't had the time to start and finish the project until now. Marlin has been good to work with and there pieces are impressive, I can't complain as they went out there way for me. I will say some instructions and parts list are simple and should be included.

 

[baxter650]

Like you i have no time constraints (especially now with broken arm and stuff) but instructions, however basic would be nice.
By the way i like your X member.

 

[nailed]

Thanks on the crossmember 650. Your build is crazy, I have been watching it since the start, you have skill. I was going to bob mine but dicided agaist it, to much for me to take on at once. I would like to later after it is running. Have you tested that gas tank yet? How much fuel did you get in there?

 

[IrollwithTojo]

I wanna toybox
Great write up

-Carl

 

[alaska60]

thank you for this write up........I'm next!