Fitting Dual-Transfers to a hilux

Post by **Toyo Truck** » Mon Dec 11, 2006 12:11 pm

Hey guys,

As y'all know, I am going up in the tyre world soon. But before I do that
I wanna fit these dual transfer cases I got sitting here.
The cases are already bolted together with the adaptor and I have
a cross member to suit.

What is the easiest way to get the duals into their new home?

I have never done this so would like to know the easiest way to do it
before I start just undoing bolts here and there,

I've heard you can leave the gearbox in (supported by jack)
and just unbolt the transfer case off the back of it and swap over to the
duals and bolt them up, then bolt the crossmember to the chassis?

Is this about right?

Cheers,
Bart

Post by **sierrajim** » Mon Dec 11, 2006 1:49 pm

Toyo Truck wrote:Hey guys,

As y'all know, I am going up in the tyre world soon. But before I do that
I wanna fit these dual transfer cases I got sitting here.
The cases are already bolted together with the adaptor and I have
a cross member to suit.

What is the easiest way to get the duals into their new home?

I have never done this so would like to know the easiest way to do it
before I start just undoing bolts here and there,

I've heard you can leave the gearbox in (supported by jack)
and just unbolt the transfer case off the back of it and swap over to the
duals and bolt them up, then bolt the crossmember to the chassis?

Is this about right?

Cheers,
Bart

Thats the way i did it.

Just tape up the gear shifter holes in the top of the cases before you install them. This way no junk drops into the cases while you install them and cut the extra hole in your floor for the second shifter. Much easier than stuffing rags in the holes.

Post by **Toyo Truck** » Tue Dec 12, 2006 4:29 pm

Sweet,

Can you answer some more simple duals-noob questions for me?

How long did it take you from start to finish to get the transfers in
and crossmember bolted up?

Did you bolt the transfer cases to the crossmember before or after
bolting the transfer cases to the back of the gearbox?

Can you roughly measure where you cut your 2nd hole?
(measure from the back of the first "stock" hole)

How many people do I need to help me do this swap out?
(to make it easier and quicker)

Cheers,
Bart

PS Is your truck single cab or extra cab? or a 4 runner/ute conversion?

Post by **Toyo Truck** » Thu Dec 14, 2006 9:13 am

Can anyone else lend any advice on this procedure?

thanks,
Bart

Post by **Gribble** » Thu Dec 14, 2006 11:22 am

Toyo Truck wrote:Can anyone else lend any advice on this procedure?

thanks,
Bart

If you want a hand and you have all gear I can help you, but not for a few weeks.

Post by **Toyo Truck** » Thu Dec 14, 2006 11:27 am

thanks man,
that'd be sweet.

I was under the truck the other day, I can see all the bolts we need
to get at and all that, so it can't be too hard.

A couple of weeks is good cause my back is still on the farked side.
Definately wanna do this soon though.

Cheers,
Bart

Post by **sierrajim** » Thu Dec 14, 2006 12:45 pm

Toyo Truck wrote:Sweet,

Can you answer some more simple duals-noob questions for me?

How long did it take you from start to finish to get the transfers in
and crossmember bolted up?

Did you bolt the transfer cases to the crossmember before or after
bolting the transfer cases to the back of the gearbox?

Can you roughly measure where you cut your 2nd hole?
(measure from the back of the first "stock" hole)

How many people do I need to help me do this swap out?
(to make it easier and quicker)

Cheers,
Bart

PS Is your truck single cab or extra cab? or a 4 runner/ute conversion?

Took me less than an hour to fit the cases. They were alreay mounted to the adaptor.

I supported the gearbox with a jack, removed the old case, bolted in the new ones, bolted the mounts to the cases, lifted the x member into place, bolted it up, cut the hole in the floor with an air hacksaw then drove it.

Post by **Roctoy** » Thu Dec 14, 2006 12:45 pm

don't forget bart, your driveshafts will need to be lengthenned and shortenned.

Chris

Post by **sierrajim** » Thu Dec 14, 2006 12:46 pm

BTW, i did it on the hoist which would make it a lot easier.

Post by **Toyo Truck** » Thu Dec 14, 2006 12:49 pm

I don't have a hoist.
But I got a bit of lift and a 2.5" bodylift so getting to stuff
shouldn't be too hard.

Can you measure the distance roughly from the end of your
original hole to the start of the second hole?

Chris,
how much will it cost me to get my rear driveshaft shortened?

Cheers,
Bart

Post by **-Richo-** » Thu Dec 14, 2006 5:46 pm

around about 160 bucks for driveshaft shortening at metropolitan, granville.

have a look on pirate Bart in the faq, im sure there would be a heap of info on dual transfers.

Post by **dominic** » Thu Dec 14, 2006 8:16 pm

dude,
give me a call when you looking a doing the swap,ill come give ya a hand if i can.
i also have a short single peice rear tail shaft up for sale.
about 1145mm from memory

cheers
Dom

Post by **Roctoy** » Fri Dec 15, 2006 11:24 am

Toyo Truck wrote:
Chris,
how much will it cost me to get my rear driveshaft shortened?

Cheers,
Bart

and your front one lengthenned too! Pretty hefty, i just went to the wreckers and bought some that were the right length (i was very lucky)

i had a long slip spline put in the front one but it cost an arm and a leg. Like $500, shop around the driveshaft places.

Chris

Post by **Toyo Truck** » Sat Feb 03, 2007 4:30 pm

Hey Guys,

I was just cleaning the duals down and I have noticed there is a
bolt missing from the bottom of the dual adaptor.
Seems to be some sort of filler plug or something?
How big is this bolt? where can I get another one??

Cheers,
Bart

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