"ultimate" h55f 5spd conversion combo

[orangefj45]

before you make your decision, let me ask you this:

what do you plan on doing with the 40? will it be street driven, trail ridden, wheeled or hit some of the more hardcore trails?

two more things to ponder when doing the swap you're considering:

1) the top cover of the h55f is taller than the earlier 4spd counterparts. so unless you have a bodylift, you will need to modify the trans tunnel since the center section will need to be raised to accomodate the taller top cover on the trans. the shifter also exits the cover about 4" ( don't quote me on this but i can measure it ) further back so the tunnel needs to be modified no matter what.

2) if you were to run that geartrain combo, the i would strongly urge you to run an x-member under the trans or under the toybox to support the weight properly. running the stock mounts off the bell housing would put a lot of stress on them.

hth

georg

 

[Blue77FJ40]

before you make your decision, let me ask you this:

what do you plan on doing with the 40? will it be street driven, trail ridden, wheeled or hit some of the more hardcore trails?

All of the above, except my hardest hardcore is only black trails.

Much as I'd like a 5 spd w/toybox, it's looking like too many necessary mods are in order...

I wonder if anyone else has gone this route?

 

[orangefj45]

well, with the h55f, split case and stock gears you're going to be at roughly 47:1 gearing. running 33s you should be able to tackle just about anything on your list with that setup. the toybox would be complete overkill but the 5th gear OD will be great on the highway.

one of the guys running rubithon with me later this week has a toybox in his 40 along with an h42 and early t-case behind the stock 2F. he's on 35s and has dual ARBs, first trip up there for him so we'll see how it goes. i doubt he'll be in "double low" more than 1% of the entire trip.

on the other hand, my wheeling partner greenfox runs the stock F with an h42 and orion, stock axle gears, front and rear lockers on 36s. we've done the trail numerous times with this rig along with running many other trails. his was the first orion i built about 4 years ago or so. the setup works great and has been super reliable although at times it would be nice to be geared a little lower for the hardest obstacles. but a slight throttle bump at the right time will keep his rig from stalling. his final ratio is 57:1 but he's on a taller tire than you are.

ask me, you can spend the $2k elsewhere on the rig and get a lot more bang for your buck. don't get me wrong, i like the toyboxes and i have installed and sold them but for your application, it's overkill.

georg

 

[Blue77FJ40]

Georg, the 4:1 orion/2F/H42 gives me sufficient low for most obstacles, but there are times I'd like lower. As Mark Whatley mentioned with his orion experience, he had to keep shifting in and out of low, and didn't have the flexibility of a normal low of about 2:1 that would have allowed him to shift with the tranny, but rather had to go either hi range (too hi at times) or to orion low range (too low at times). With the toybox (2.28)/orion, the regular low would be regained such as for sand running, and stupid low is there for the few times needed.

Currently, what holds me up mostly is my clearance - sua 4"/33s. For the black trails here in the east, 35/36s are better and I'd need to cut for that. At present, I'm holding off on that, but one never knows. Your feedback is invaluable.

 

[orangefj45]

Georg, the 4:1 orion/2F/H42 gives me sufficient low for most obstacles, but there are times I'd like lower.

agreed. that's where the h41 would come in very handy.

 

[rutbeer]

Groovy. That's a lot like the twin stick I did for my split/h55f on my diesel. I used all toyota parts, but made one simple bracket that attached to one of the sticks to activate the front drive. Works very well......when you use it. I did Baby lion's back in 2 high by accident. Doh!

 

[orangefj45]

got any pics of yours?! i'd like to check that out.
georg

 

[rutbeer]

Sure. I have a pic of the prototype anyway. The final one was more beefy....this one was thin enough to work as a template.

https://forum.ih8mud.com/40-55-series-tech/60600-truck-put-13bt-into-6.html

 

[orangefj45]

very cool, thanks for the link. lemme know when you're coming over to remodel my bathrooms!

 

[Diesel42]

Has to comment on your impecable work. Well done.

 

[orangefj45]

thanks a bunch. i try.

georg

 

[orangefj45]

the twin-stick kits are now completed and available for sale.

https://forum.ih8mud.com/merchandise-storefront/303124-split-case-twin-stick-kits.html

 

[abosely]

Georg,

Is the P-Brake bracket in the pics the one that comes with the TSM FJ60 P-Brake kit or did you custom build it?
I like it, sure does look robust!

I'll be ready for for one of your Twin Stick Split Case T-Case kits after the first of the year. I'll be putting a split case in a 40.

Cheers, Allen

 

[orangefj45]

Georg,

Is the P-Brake bracket in the pics the one that comes with the TSM FJ60 P-Brake kit or did you custom build it?
I like it, sure does look robust!

I'll be ready for for one of your Twin Stick Split Case T-Case kits after the first of the year. I'll be putting a split case in a 40.

Cheers, Allen

hey allen.
yes, the entire ebrake assy used on this combo is from TSM and was designed for the fj6x series cruisers. you may run into clearance issues when trying to install one of these in a 40. i doubt you'd be able to use it at all in a late 40 with the tank under the tub.
i have the twin-stick kits in stock. lemme know when you're ready.
thanks again!

georg @ valley hybrids

 

[abosely]

George,

It will be 78 & earlier type tub from Oscar (Pacol) and the frame is being stretched 12" so the cross member (the one with the hump in it) will be 12" further back.

Do you see any fitment problems using the TSM P-brake with the frame stretch or would the SOR drum version (the one with the new longer tail shaft) work better?

Cheers, Allen

 

[orangefj45]

hard to tell and i can't answer since i have not set up a 40 that way. maybe one of the guys from ipor can reply, they're installing this combo into a customers' 40 right now.

hth

georg @ valley hybrids

 

[belaw]

I researched going with either the t-case ebrake or rear disk conversion with ebrakes. It was a no brainer, you gain about 2 inches in drive shaft length with the rear disk with ebrake and it costs about the same.

What about a late model rear axle with drums and ebrake? Would it be possible to connect the cable to an early style (under dash) ebrake handle?

 

[orangefj45]

What about a late model rear axle with drums and ebrake? Would it be possible to connect the cable to an early style (under dash) ebrake handle?

sure, but why would you want to? you'd need a custom cable. also, the floor mounted ebrake assemblies give you better leverage and they're much easier to adjust and service. utilizing one out of a late 40 or any fj60/62 would allow you to use all oem components. we have grafted the fj60 ebrake assy into the 40 series rigs and it's a great mod.

hth

georg @ valley hybrids

 

[PabloCruise]

sure, but why would you want to? you'd need a custom cable. also, the floor mounted ebrake assemblies give you better leverage and they're much easier to adjust and service. utilizing one out of a late 40 or any fj60/62 would allow you to use all oem components. we have grafted the fj60 ebrake assy into the 40 series rigs and it's a great mod.

hth

georg @ valley hybrids

Do the 60 series rear drums bolt right onto a 40 housing?

 

[Cruiserdrew]

Do the 60 series rear drums bolt right onto a 40 housing?

No. The backing plate is completely different, the drums are different, the save cylinder is different and the brake adjuster is different.

But, later 80+ FJ40 housings use the FJ60 set up.