Transfer Case Idler Shaft Hole Identification Anomaly. Is it Non USA?

[Ackcruisers]

I’m preparing for a 4 speed swap and will be dropping in a 1983 H42 from an FJ60 with 40 top plate. It’s matched with a 1980 (1979 build) FJ40 transfer case. While learning about the variety of transfer cases, I came across this helpful article in 4 Wheel Off Road magazine’s August of 1997‘s issue (here is the link).

According to the image below, the one ( letter D) on lower row far right is from a non USA truck.

My existing transfer case (Image below) is mounted to a 3 speed but it appears the PO used something to reduce the diameter of the idler shaft.
Did they reduce the idler shaft diameter to accept the smaller shaft that is common with rebuild kits?

Here is another image of my case when empty, from the front. Notice idler shaft hole and ring used to reduce its diameter.

 

[3_puppies]

you are going to use a 1983 H42 with a 1 piece transfer case?
the 1983 originally had a split case transfer?
I don't think they will work together.

 

[Living in the Past]

I’m preparing for a 4 speed swap and will be dropping in a 1983 H42 from an FJ60 with 40 top plate. It’s matched with a 1980 (1979 build) FJ40 transfer case. While learning about the variety of transfer cases, I came across this helpful article in 4 Wheel Off Road magazine’s August of 1997‘s issue (here is the link).

According to the image below, the one ( letter D) on lower row far right is from a non USA truck.
View attachment 2412163

My existing transfer case (Image below) is mounted to a 3 speed but it appears the PO used something to reduce the diameter of the idler shaft.

Did they reduce the idler shaft diameter to accept the smaller shaft that is common with rebuild kits?

View attachment 2412164

Here is another image of my case (rear view) below is front empty image. Notice diameter of hole and ring used to reduce.

View attachment 2412165
View attachment 2412171

Nineteen spline tailshaft on the 8/80+ verses 16 spline on the pre 8/80 four. Good chance you transfer has 10 spline with 31 teeth input gear that would only require a input gear change if using a 16 spline four speed. Spline transfer on a 60 series will not have a hand brake. Those are available but will make your transfer longer than if it was a one piece transfer case that all have the hand brake.

 

[Ackcruisers]

you are going to use a 1983 H42 with a 1 piece transfer case?
the 1983 originally had a split case transfer?
I don't think they will work together.

Yes, according to the seller, there is something bolted to the H42 in front of the 1 piece transfer case. Both the H42 and transfer case are being removed as a single assembly from a 1980 FJ40. There must be an adapter.

 

[Ackcruisers]

After looking at the 4 Wheel Off Road magazine’s article again and comparing to my existing transfer case, it appears mine is not a Non USA type. Good pictures of one can be seen in this post by @DangerNoodle . It appears my case matches the pattern on the 7/78 - 7/80 Toyota PN 36111-60031. What I cannot figure out is the diameter of the idler shaft that should be in my case. As shown in the below images, there is something used to reduce the diameter to accommodate the smaller diameter idler shaft offered in rebuild kits.

 

[DangerNoodle]

After looking at the 4 Wheel Off Road magazine’s article again and comparing to my existing transfer case, it appears mine is not a Non USA type. Good pictures of one can be seen in this post by @DangerNoodle . It appears my case matches the pattern on the 7/78 - 7/80 Toyota PN 36111-60031. What I cannot figure out is the diameter of the idler shaft that should be in my case. As shown in the below images, there is something used to reduce the diameter to accommodate the smaller diameter idler shaft offered in rebuild kits.
View attachment 2412999
View attachment 2413001

Mine was a 34mm idler shaft. I think that is what the non US-Spec was. Talk to Kurt ( @cruiseroutfit ). I'm sure he know what it should be, and has a rebuild kit.

 

[Living in the Past]

Yes, according to the seller, there is something bolted to the H42 in front of the 1 piece transfer case. Both the H42 and transfer case are being removed as a single assembly from a 1980 FJ40. There must be an adapter.

Up to 8/80 the four speed used a one piece transfer case and other than a few that had 10 spline output shaft the rest had 16 spline output shaft. 10/80+ the output changed to 19 spline and mated to a split transfer case. H42 was made in both versions. Only the early 10 or 16 spline will work with the one piece transfer case. A split transfer case had a hand brake on the 8/80+ BJ45/FJ45/HJ47. All the others had a hand brake on the rear axle.

The 60 series started 8/80 and all of the transmissions four or five speed had a nineteen spline output shaft mated to a split transfer case. If you do go with a later split case style and may go H55F five speed later on would get a 10/82+ transfer case with the fifth gear oiler.

 

[landtank]

I’m the seller and the truck in question is a pre 8/80 built truck. What he is looking at is the h42 with the original t-case from that truck as an assembled piece.

Originally I thought the two H42s were the same and was just going to swap over the t-cases but have since realized that isn’t an option. Which has caused some confusion.

this is my first time getting into my 40 and am learning as I go.

 

[Living in the Past]

Originally I thought the two H42s were the same and was just going to swap over the t-cases but have since realized that isn’t an option. Which has caused some confusion.

Think these two posts created some confusion.

I’m preparing for a 4 speed swap and will be dropping in a 1983 H42 from an FJ60 with 40 top plate. It’s matched with a 1980 (1979 build) FJ40 transfer case.

Yes, according to the seller, there is something bolted to the H42 in front of the 1 piece transfer case. Both the H42 and transfer case are being removed as a single assembly from a 1980 FJ40. There must be an adapter.

The biggest hurdle to using a one piece transfer case on a 8/80 19 spline tailshaft H42 is finding a transfer input gear which would have to be custom made. The one piece transfer was a made a couple of years after 8/80 but those were only for the J30 three speed with 10 spline tailshaft.

I know I'm just trying be helpful as I'm sure Paul @3_puppies is. Certainly was accusing anyone of trying sell something they knew wouldn't fit. Sorry if there was any confusion.

 

[Ackcruisers]

Think these two posts created some confusion.






The biggest hurdle to using a one piece transfer case on a 8/80 19 spline tailshaft H42 is finding a transfer input gear which would have to be custom made. The one piece transfer was a made a couple of years after 8/80 but those were only for the J30 three speed with 10 spline tailshaft.

I know I'm just trying be helpful as I'm sure Paul @3_puppies is. Certainly was accusing anyone of trying sell something they knew wouldn't fit. Sorry if there was any confusion.

Thanks for your help. Much appreciated as I’m trying to wrap my head around this. The confusion stemmed from the fact there are two H42’s (I was not aware). @landtank was kind enough to offer me the complete stock H42 + one piece tcase that is attached to his 1980 (79 build date) FJ40. He has another H42 from a 1983 FJ60 that he is using with a two piece transfer on his 1980 build. This was what confused me.

FYI: @3_puppies your 1975 harness is successfully powering my 1976 FJ40.

 

[mattcamp]

I’m preparing for a 4 speed swap and will be dropping in a 1983 H42 from an FJ60 with 40 top plate. It’s matched with a 1980 (1979 build) FJ40 transfer case. While learning about the variety of transfer cases, I came across this helpful article in 4 Wheel Off Road magazine’s August of 1997‘s issue (here is the link).

According to the image below, the one ( letter D) on lower row far right is from a non USA truck.
View attachment 2412163

My existing transfer case (Image below) is mounted to a 3 speed but it appears the PO used something to reduce the diameter of the idler shaft.
Did they reduce the idler shaft diameter to accept the smaller shaft that is common with rebuild kits?

View attachment 2412164

Here is another image of my case when empty, from the front. Notice idler shaft hole and ring used to reduce its diameter.

View attachment 2412165

I don't think yours is the non USA (D) case. Yours looks like a standard USA casting that has had the idler shaft hole bored and sleeved. There are more differences in the D case besides the hole diameter, it has more gussets between the input shaft bearing and the idler shaft hole and also differences along the top plate. Maybe there was too much tolerance in your case. You won't be able to use a 1983 h42 with a solid case, can you get the split case from the fj60 also?

 

[Ackcruisers]

I don't think yours is the non USA (D) case. Yours looks like a standard USA casting that has had the idler shaft hole bored and sleeved. There are more differences in the D case besides the hole diameter, it has more gussets between the input shaft bearing and the idler shaft hole and also differences along the top plate. Maybe there was too much tolerance in your case. You won't be able to use a 1983 h42 with a solid case, can you get the split case from the fj60 also?

Thanks for your input. I’ve also concluded it is not a non USA case given the other details. The 1983 h42 is not what I ended up with. I have an H42 and transfer case from a 12/79 FJ40. Just picked it up tonight (image below) and will clean it tomorrow.

 

[mattcamp]

Thanks for your input. I’ve also concluded it is not a non USA case given the other details. The 1983 h42 is not what I ended up with. I have an H42 and transfer case from a 12/79 FJ40. Just picked it up tonight (image below) and will clean it tomorrow.
View attachment 2415332

Nice!

 

[mattcamp]

I'm piecing together a 4sp with a 3sp t-case currently. I just got the conversion gear and bearing from Valley Hybrids and mated them today. Not sure what year the tranny is but the t-case is a '73.

 

[Ackcruisers]

I'm piecing together a 4sp with a 3sp t-case currently. I just got the conversion gear and bearing from Valley Hybrids and mated them today. Not sure what year the tranny is but the t-case is a '73.View attachment 2415345View attachment 2415347

Looks great. What did you do to clean up the aluminum transfer case? Also, what’s the black bracket on the top of tcase?

 

[DangerNoodle]

Looks great. What did you do to clean up the aluminum transfer case? Also, what’s the black bracket on the top of tcase?

Wire wheels clean the aluminum really well. That's what I've been doing.

 

[Living in the Past]

Thanks for your input. I’ve also concluded it is not a non USA case given the other details. The 1983 h42 is not what I ended up with. I have an H42 and transfer case from a 12/79 FJ40. Just picked it up tonight (image below) and will clean it tomorrow.
View attachment 2415332

I personally don't think the D style is not as much a non US case as a 8/80-10/82 case that was still used with the three speed in markets that were still getting a three speed. Looking around different markets I see the same case numbers up to 8/80 in all markets no matter if it was a three or a four speed. There was part number changes but those happened the same in all markets I checked. 8/80 the part number changed again for the one piece case. Idler shaft part number changed also. Remember back in the early nineties friend who was retired use to rebuild one piece transfer cases. He had one of the larger idler changes that was a mystery. At the time wasn't know that the three speed and one piece case were used into the eighties. Was know some markets got a three speed after US got the four speed just not that long. Think it been brought some parts from the early 34 MM idler split case can be used to rebuild these late one piece cases. Since US never got them after 8/80 serious doubt the parts system even have these listed. I know I check a lot of non US part numbers on a local dealer's site and most come as no such part number.

 

[mattcamp]

Looks great. What did you do to clean up the aluminum transfer case? Also, what’s the black bracket on the top of tcase?

Brake cleaner, wire brushes and elbow grease, I hate doing it but it sure helps when you're working on it. That black bracket is a case saver, not sure how well they work but they are cheap. I have used them on 6 or 7 cases and cracked a couple of them but not down the middle. I've only cracked 4sp cases, never a 3sp.... Don't know if it means anything, just an observation.