Upgrades for the coming season

This site may earn a commission from merchant affiliate
links, including eBay, Amazon, Skimlinks, and others.

Joined
Aug 27, 2008
Threads
40
Messages
3,893
Location
Calgary Alberta
The "just bought it thread" ----> here

A caveat before we start - this BJ42 is all original and I will not be the PO who hacks it all up. I have another build that is all custom but all mods on this 42 must be "un-doable". I intend a full nut and bolt restoration on this truck some day and have been collecting parts to that end already.


After 22,000 km last year I have a few things I want to change for the upcoming wheeling season.

These are the issues:

1) Power. Need some. The normally asphyxiated 3B has enough power to tool around the city with no issues at all. Her favorite speed is right around 80km/h. The highway is another matter. With no wind on level ground she'll do 110km/h with relative ease. A headwind or any incline whatsoever is like throwing out an anchor. And most of the 22k km last year was hwy.

2) Gearing. The current gearing is all stock H42/2.28/4.11 with 10% rubber overdrive. It works good but can be stressful on certain high risk obstacles. Without enough power to push through I have often stalled at quite inconvenient times.

3) Front diff. It's open and I had at least three specific occasions where a front locker would have gotten me through.


My solutions are:

1) Turbo. Go head and say it Josh.

2a) Advance Adapter's 4:1 transfer case gears.

2b) H55f

3) ARB and compressor.


I will be pulling the entire stock original drive train out and mothballing it for that future restoration. There is nothing wrong with it and only 200k on the clock.

I had a 3B rebuilt at great cost for my 45 project using many new components and a t3/t4 turbo. The 45 project is going another direction and this engine is getting dusty. I sourced an H55f/splitcase (from Behemoth60) out of a 86 BJ70 but it has over 650,000km on it. I also purchased a brand new H55f from Beno and AA's 4:1 gears purchased through Kurt.

This combo does a number of things differently than the stock train did. Turbo for more power. 5 speed gives lower first gear and a 15% overdrive. The 4:1 case gears give me a 77:1 low/low and another benefit. The lesser known effect of the 4:1 AA gears is the 10% under-drive in high range. At first I thought that was a bad thing until I realized that the 33" KM2's give me near enough to a 10% rubber overdrive.

Net effect is a corrected speedo and 5% overdrive with a turbo to power it and low enough crawl to stop a lot of the herky-jerkies.

Feel free to point out any errors in my math. Here are some pictures.

The 42
IMG_3363.webp

The 3B originally built for my 45
IMG_1256.webp

The new H55f from Beno
IMG_4141.webp
IMG_3363.webp
IMG_1256.webp
IMG_4141.webp
 
Last edited:
The gears.
IMG_4132.webp

The Locker
IMG_4136.webp

The twin 24V compressor.
IMG_4138.webp
IMG_4132.webp
IMG_4136.webp
IMG_4138.webp
 
The high mileage donor. This will supply the input shaft and bell housing as well as the cases and a few internal transfer case parts.

IMG_4145.webp

IMG_4146.webp

The wrong input shaft

IMG_4142.webp
IMG_4145.webp
IMG_4146.webp
IMG_4142.webp
 
I'll end tonight with a brain teaser.

What part am I using off of this assembly. This is from my 45 project. P1010025_18.webp

P1010010_2_2_2_3.webp
P1010010_2_2_2_3.webp
P1010025_18.webp
 
Thanks Sarge

Damn! First guy to guess got it.

I don't want to cut the 42 transmission cover so I'll use the top plate off of the setup I made for the 45. I may end up making a custom cover anyway because the transfer case shifters are going to move but I'll swap top plates anyway. If the stock transfer shift lever won't line up I will throw on the twin stick setup I got from Georg. May as well if I have to make a cover anyway.

I paid $2089.00 US for the tranny three weeks ago. Call Beno. Canadian dealers want $3800.
 
For petinjp

IMG_4144.webp
IMG_4144.webp
 
Reason being I covet that shifter plate.... I tried and tried to locate one in north america and even tried to get one out of oz. I guess I just didn't try hard enough!

have you contacted Shawn at MetricTLC ?
 
I got this one from a CDN mine truck but I bought the whole truck for the drive train. At the time I was not aware of the rarity of the top plate. I just wanted the 3B/5spd combo
 
The other day I decided I had better get busy so I started to dismantle the t-case. The back case half need to be clearanced for the larger diameter gears. I have access to a machine shop through work so I will get them to mill down the case.

Not a lot of oil in there :eek:

IMG_4147.webp

And interesting sealing technique on the rear output splines.
IMG_4148.webp

IMG_4150.webp
IMG_4147.webp
IMG_4148.webp
IMG_4150.webp
 
All of the teeth are still there at least. Though I don't really care with all new gears going in.

IMG_4152.webp

IMG_4153.webp
IMG_4152.webp
IMG_4153.webp
 
Someone in the past got a little rough on the bearing holder.

IMG_4158.webp

IMG_4157.webp
IMG_4157.webp
IMG_4158.webp
 
Rear case cleaned and ready for the machine shop

IMG_4161.webp


Then I got the jack stands out and pulled the shafts out to start on the ARB install.
IMG_4160.webp

After all the work involved to get the diff on the bench I decided it was stoopid not to replace the gears too. So I called Bryce at Cruiser Outfitters and got him to send me a set of 4.11's. These likely have 200k on them and have almost 0.025" of backlash. So the locker install is on hold until the gears get here.
IMG_4162.webp
IMG_4161.webp
IMG_4160.webp
IMG_4162.webp
 
winning pic right there :cheers:

you are likely familiar with that spot but for those that aren't it is the lunch break spot at the end of the Porcupine Rim trail in Moab.

Notice the acreages down in the valley... that's a straight vertical drop.
IMG_3354.webp

The view 90º to the right.
IMG_3366.webp
IMG_3366.webp
IMG_3354.webp
 
Back
Top Bottom