Wasn't sure if I was going to get this thing back together in time for KY. The crawl ratio on this thing stinks. And I wasn't able to take advantage of the 5spd H55 Aussie transmition that's in this thing, I couldn't even use 5th gear unless I wanted to go 80. So I took the axles apart yet again, wish I would have just done this when I installed the Aussie lockers. Went with 5.29s. We'll see if that small pinion holds up. Took the 3rd members to Paul C and I'm glad I did. He does good work; I was going to try it myself this time but one of the threads on the pinion gear galled really bad and become a big snag and delay in the process. The other thing that sucks is the rear uses c-clip axles so we had to grind a heck of a lot off a ring gear tooth for the center pin clearance. Now to go break these things in. It's still a crappy final ratio, but a heckuva lot better than before.
Nice to see someone's project making headway. Are you sure you guys ground the correct tooth? I think you might be 180 out.
If you said that to make me go out and look then it worked. If you look at the last pic you can see where the pin bolt boss and recess in the pin hole. Actually its already back together. Just need a helper so i can bleed the front breaks. Then go for a ride and break the gears in.
See if you and machmer could get a job with shift werk like jason and i, you'd get yer junk fixed during the day when no ones home.
Don't worry about it Keith it is only a little bit of the tooth. Heck i ran mine with 1 1/2 ring gear bolts for at least a month. Not intentionally but, it worked.
2005 F350 Oil Burner
2007 Jeep XK SOLD
2001 Jeep TJ SOLD
2000 Jeep XJ SOLD
1999 Jeep TJ (Ryans Ride)
1998 Jeep XJ SOLD
1975 CJ6 (OH YEAH) Currently Upgrading
Ricers are like penguins...small, slow, and have useless wings.
Holy Crap I've been off the net WAY too long. I first learned a few days about Keith's FJ40. I hope to stop by this week and check it out. I can share LOTS of lessons learned, especially on the birfields. I have the 30-spline shafts and birfs from Longfield. Bobby says their stronger than D60s. I've not had problems.
Looks like you're building to try and keep him street driveable. Many days I wished I had that with mine, but after a certain amount of cutting and welding, it's not possible. Can't wait to see it and wheel with it.
Fran
Fran B 73 ToyotaFJ-40 99 Toyota Taco 07 Toyota FJ Cruiser 08 F-250 SD TD 18 ft plain old trailer...
Good to hear from you again. For now I'd like to drive it on the street. If it starts to get beat up too bad then I'll turn it in to a trail rig. And if it stays together maybe I'll restore the tub and floor pans one day. I have a few things I'd like to do, but a few friends are keeping me from getting carried away.
Here's some more work Eddie has done for me. He does great work. I asked him to tie in the front cage to the frame and reinforce the rocker guards to the frame. Well he managed to tie both the cage and rockers all together very strong front and back and exceed my expectations. I also asked him to make me a tire carrier that would allow the tire to fit in the back and have it stand upright. Again, he made something that I couldn't have even imagined. And last, he welded in some tube on the cage and some grab handles. He sent a couple phone pics, I'll see about getting more when I get it home and painted up.
The one jump seat had to come out, but he made it so I can unbolt the tire carrier and bolt the seat back in if I ever wanted to haul 4 people.
I removed the turn signals and will be trimming the fenders some more. Found some neat headlights with built in LED signals. At night with the lights on it does wash out the signal light some, but not nearly as bad as the camera shows. The glare is preventing me from getting a good photo but you get the idea.
It's time for some more build up action. Haven't had interest in doing much to this thing, but one thing I've always been disappointed in is the low range gearing. With a 1st gear of 4.8x1.99low range x 5.29 R&P = a dismal 50:1 final gear ratio. On 35's that pretty much sucks in the rocks. There's been a set of 3.05 gears available for my split case but there are crazy expensive and I wasn't willing to spend the $ for that little difference in gearing. Advance Adapters just came out with some 4:1 gears so I pulled the trigger on those. They are still expensive, but not crazy expensive, so what the heck. These will double by crawl ratio, netting me 102:1 which will be awesome. So when I remembered I snapped a few photos. I'm not done yet, it got hot today and I really don't know what I'm doing in regards to this Toyota split case...it's a lot different than a D300.
First, remove the t-case skid, speedometer gear, rear driveshaft, rear output shift lever, parking brake drum and backing plate, and the PTO inspection cover.
Remove the bolts on the rear case and remove the case. That front output cluster should have stayed with the front part of the case but it came out with the rear. No biggie, just make it more difficult because it was unexpected.
Last Edit: Jun 13, 2011 20:12:32 GMT -5 by Deleted
Now I need to figure out a way to hold the input cluster so I can loosen the nut on the shaft. Then it's a matter of pulling everything off, removing 4 more bolts, and pulling the front half of the case off. Idler cluster and front output cluster:
The rear case is completely disassembled and ready for some machining.
It needs to look like this for clearance for the larger gear:
That is all for now, I still need to get the main input shaft removed and see what type of input it is. It may require a different shaft I will have to source, not sure yet.