Mating an R151 gearbox to a G52 Transfer Case

[ferrit]

Yeah, Im nuts.


Ive got a 3.0TD surf halfcut to be a donor motor/box for my hilux 2.8D.

The surf comes with a 1KZ-TE motor, R151F gearbox, and a Chain drive, electric shift transfer case.


What i want to do is to use the old gear driven transfer case from the G52 gearbox (in the lux already) with the new gearbox.

The problem is that the R151 is a 26 Spline output shaft, and the G52 is a 24- so the G52 transfer case is a 24 input.

Im just trying to work out the best way to go about doing this!

I thought there was an easy adaptor from marks that allowed you to mate them up, but apparently its for top shifting transfer cases only, not the front shift ones like the suft and lux has.

The other option im looking at is when i pull the transfer case down to rebuild it (340,000kms old!) i'll get the input shaft rebuilt and re-splined to suit the R151 output.


Anyone done anything mad like this before? and how did you go about doing so?

[v6hilux]

It may be possible, but the the G and R are 2 different shapes. You would need an adapter plate too.

I think you may find there is a gear type xfer that will go to the R, but not sure.

[dogbreath_48]

Marlin crawler make an adapter plate to fit the gear drive xfer to R series box. You'll also need a 23 spline input shaft for the transfer case - the marlin kit comes with an adapter (to suit a 23 spline shaft).

These are both available from locktup4x4.com.au - where my brother sourced his from - to mate a 2L-t R box to 3L/g52 xfer.

-Stu

[RUFF]

Yeah, Im nuts.


Ive got a 3.0TD surf halfcut to be a donor motor/box for my hilux 2.8D.

The surf comes with a 1KZ-TE motor, R151F gearbox, and a Chain drive, electric shift transfer case.


What i want to do is to use the old gear driven transfer case from the G52 gearbox (in the lux already) with the new gearbox.

The problem is that the R151 is a 26 Spline output shaft, and the G52 is a 24- so the G52 transfer case is a 24 input.

Im just trying to work out the best way to go about doing this!

I thought there was an easy adaptor from marks that allowed you to mate them up, but apparently its for top shifting transfer cases only, not the front shift ones like the suft and lux has.

The other option im looking at is when i pull the transfer case down to rebuild it (340,000kms old!) i'll get the input shaft rebuilt and re-splined to suit the R151 output.


Anyone done anything mad like this before? and how did you go about doing so?

Your gear driven case is actually 21 spline input. They only came to Australia with the 21 spline input.

You will need to find an early 4spd Transfer case(Top Shift) and then buy these 2 items from Marlin-

V6(Rseries box)-Chain Drive Adapter $349 US



23 spline Chain Drive Input gear- $159 US



Both listed on this page- http://www.marlincrawler.com/htm/transf ... p_dual.htm

There is no adapter to suit the Forward shift transfer.

Marlin also used to list a Forward Shift to Top Shift Conversion kit but its no longer listed. it may be worth asking them.

These items from Marlin are available in Aus from the Guys at www.lockedup4x4.com.au http://www.locktup4x4.com.au/product/a6 ... 228f2.aspx

[dogbreath_48]

Your gear driven case is actually 21 spline input. They only came to Australia with the 21 spline input.

You will need to find an early 4spd Transfer case(Top Shift) and then buy these 2 items from Marlin-


Marlin also used to list a Forward Shift to Top Shift Conversion kit but its no longer listed. it may be worth asking them.

Bro reckons he can use the shifter flange from R series, and use extended gear driven x-fer stick

[locktup4x4]

Marlin doesn't sell the Forward Shifter to Top Shifter conversion kit at this time.

Jason

[RUFF]

Bro reckons he can use the shifter flange from R series, and use extended gear driven x-fer stick

I would check with Marlin. Your Bro could be right. I just realised Marlin doesnt mention having to use a top shift case.

[ferrit]

hrmmm.....

Id rather NOT use the electric shift transfer case if i can (might have to source a Hilux TD transfer case with the standard lever shift, and keep the stupid chain drive transfer case.

Wonder if a 1HZ R151 is the same as a 1KZ R151? I dont think the 105s and 79 series have chain drive transfer case?

[RUFF]

Wonder if a 1HZ R151 is the same as a 1KZ R151? I dont think the 105s and 79 series have chain drive transfer case?

I thought they were H150 or H151 in the Cruisers? Im pretty sure these are a different animal than the R series box.

[ferrit]

Well i was just at the marks 4wd website.

http://www.marks4wd.com/products/advanc ... _CD_GB.htm

Hilux/4Runner Vehicles fitted with the chain driven transfer case are handicapped when it comes to low range gearing options. Advance Adaptors recognised this problem and so have designed this kit to fit the gear driven transfer case in place of the chain driven type thus allowing the extra low gears to be fitted or the dual transfer case option.

Marks 4WD Adaptors have designed two new coupler sleeves that when used with the adaptor plate from the Advance Adaptors kit allows the common Australian gear driven 21 tooth transfer case to be used. The first coupler suits the 26T spline G52 5-speed as found behind all 4-cylinder models except the factory 3ltr turbo diesel. The second coupler suits the 23T spline R150 gearbox as found behind the factory 3lt turbo diesel and all V6 models.

Please note you will need to purchase a donor gear drive transfer case from a 5-speed model post 1984 for installation in your vehicle when using the following kit.

By the sounds of it, they are saying you can still use your forward shift transfer case from your 5 speed box, and mate it to the R151 gearbox- Im just not sure how many spline my R151 gearbox has!

[toyrex]

R15# is 23 spline
G52 with geardrive transfer is 21 spline
G52 with chaindrive transfer is 26 spline
I have grafted the R151 housing onto the G52 housing and made a 23/21 spline couplers
I am wanting to cast some housings now

[Highway-Star]

hrmmm.....

Id rather NOT use the electric shift transfer case if i can (might have to source a Hilux TD transfer case with the standard lever shift, and keep the stupid chain drive transfer case.

Wonder if a 1HZ R151 is the same as a 1KZ R151? I dont think the 105s and 79 series have chain drive transfer case?

If you ever want lower low range do the gear conversion now, it will save allot of hassel, if not the chain drive TC has a slightly lower low range than the geared one anyway (about 2.6 vs 2.3 I think).

My father and I are currently beginning the process of trying to figure out the 2-4 shift mechanism on the electric case, and it is a PITA for electrical novices like me! I wish my father would do what you are looking into and adapt the gear case, but he fails to see the beauty of crawler gears.

The HZJ79 did use an R151f box for a couple of year (around 2001 I think) apparantly these are the ones that have a habit of throwing the main shaft, the H151 box really is better for the torque out of the HZ engines. However forget all this, as the criser transfer is a Royal pain to adapt to the Hilux as its significantly larger, and has the rear output offset like the front. Was looking into this option myself for Dads car a while ago.

As for the spline count on your individual box, I'd recomend cracking it open and having a look, as I've found that many different R boxs that look the same but are not, it gives me a throbbing headache. I even did find mentioning of am early one (mid 80's) that had a gear transfer on it from factory, but still had a electric shift mechanism. I don't know what vehicle it was out of though.

[ferrit]

Yeah- I'll drop the transfer off the back of the gearbox this weekend, then i can give marks a ring and go "will this work?"

[ferrit]

Just got a reply from Marks 4wd- From Mark himself!

Hi James,

As per our telephone conversation, confirming that the MFK1598 will bolt the R151F gearbox to your gear driven transfer case. You need to check the spline count 23 or 26 for the correct kit. Kits are in stock

Kind Regards
Denny


Now.... i need $600 to buy the thing

[RUFF]

Just got a reply from Marks 4wd- From Mark himself!

Hi James,

As per our telephone conversation, confirming that the MFK1598 will bolt the R151F gearbox to your gear driven transfer case. You need to check the spline count 23 or 26 for the correct kit. Kits are in stock

Kind Regards
Denny


Now.... i need $600 to buy the thing

Why did Mark sign off as Denny?

[bulldogy]

Marlins adaptor for the R150 can be used with a forward shifting case the rail goes thru the top slot all you need to do is lengthen the shifter lever by approx 15mm.

You should have a 23 spline output on that chain case.

All you need is a forward shift Gear case a 23 spline input gear and the adaptor plate from marlin to make it work.

Dave

[ferrit]

Denny is the nice girl on the phone who went and asked mark for me!

And id rather NOT pull the chain drive case apart- theyre worth a grand in good nick down here in SA! I'll be selling the stupid thing to recoup some of the $6200 the halfcut cost!

[pulux]

Did this a while ago... bulldogy is on the money. I would go the marlin kit though, I used the AA one from Marks and one of the seals doesn't fit very well, gotta widen the hole in the adaptor plate.

Extend your transfer shifter by 15mm, grind the transfer around one of the bolt holes and use an allen head bolt for clearance, and you're away.

[Grublux]

I had the same issue with the Advance one from Marks as pulux did. One of the seals was no where near fitting.

[leehamescort]

Well I'm very confused but this is the topic I needed right now too, thanks guys.

How do I know if its a forward or top shift transfer?

I have dual gear drive transfers with a G series box (the g series box went bang)
I want to mate them up to the R151 that was originally in the surf.

The transfers have a 21 spline input.

If they are top shifting transfer, do I not need to extend the shaft? Does the same adaptor and input from marlin still work?

Do I have to use anything from the chaindrive transfer originally on the R series box? This has crawler ratios in it so I'd like to sell it complete so I dont want to have to pull it apart.

Thanks for the info.

Regards
Leeham

[RUFF]

Well I'm very confused but this is the topic I needed right now too, thanks guys.

How do I know if its a forward or top shift transfer?

I have dual chain drive transfers with a G series box (the g series box went bang)
I want to mate them up to the R151 that was originally in the surf.

The transfers have a 21 spline input.

If they are top shifting transfer do I not need to extend the shaft? Does the same adaptor and input from marlin still work?

Do I have to use anything from the chaindrive transfer? This has crawer ratios in it so I'd like to sell it complete so I dont want to have to pull it apart.

Thanks for the info.

Regards
Leeham

I think your confused. You either have a custom one off Chain Drive Dual case set up and a custom one off crawler geared chain drive transfer or you actually have Dual Gear driven cases and crawler gears to suit which are both commonly available?

[leehamescort]

Whoops, sorry, edited the post. My typing fingers got confused

I have a gear driven twin transfer setup on the stock hilux box.

I want to bolt the twin transfers up to the R series surf gearbox. Looks like the Marlin kit is right for this.

The R series box has a chaindriven transfer with crawler ratios (was from a one off batch that I dont think are available anymore, so im told)
I want to take the chaindrive tranfer off complete and sell, so dont want to canabalise it for parts. It sounds like I dont need to from the marlin website.

I am confused as to the top and front shirt transfers? how do I know which is which? Will either work with the marlin setup.

Thanks.
Leeham

[RUFF]

If you are running the G series box then you should have a Farward and a top shift case fitted. The front reduction case will be a forward shift and the complete rear case is a top shift. If you look at your reduction case you will see the transfer stick actually comes out of the gearbox tail housing(Forward Shift). Where as the rear case the stick comes out of the top of the reduction housing(Top Shift)


Where were these reduction gears in the chain drive case made? I have never heard of any company ever offering a set. Your not getting confused with the fact the chain drive case has lower gearing than the gear drive case from factory are you? 2.28 in the gear drive to 2.66(i think) in the chain drive case.

The marlin kit will work for what you want to do.

[bulldogy]

A forward or top shift will still work with the adaptor, to find out what you have all you need to do is look where the Tcase lever goes into, if it goes straight into the T case then it is top shift if the lever goes into the extension housing between the case and gearbox then it is a forward shift and you will see a blanking plate on the transfer case.

[Sic Lux]

I am confused as to the top and front shirt transfers? how do I know which is which? Will either work with the marlin setup.

Thanks.
Leeham

Pics hope it helps man.
Foward shift

Top shift

[v6hilux]

[quote="Sic Lux"]Pics hope it helps man.
Foward shift
[img]http://i152.photobucket.com/albums/s162 ... dshift.jpg[/img]
Top shift
[img]http://i152.photobucket.com/albums/s162 ... pshift.jpg[/img][/quote]

I'm assuming the top pic is R and bottom is G?

Do you have pics to show the difference in R and G type?

[gotoy]

Am I missing something here??

He's bought a halfcut 1KZ and R151F gearbox combination.

Why is the old G52 being used and not the R151F?

After all the R151F is stonger. No need to mess around with adaptor plates etc etc.

[Sic Lux]

Am I missing something here??

He's bought a halfcut 1KZ and R151F gearbox combination.

Why is the old G52 being used and not the R151F?

After all the R151F is stonger. No need to mess around with adaptor plates etc etc.

He's using the r151f box but going to a gear driven transfer

I'm assuming the top pic is R and bottom is G?
Do you have pics to show the difference in R and G type?

I'd asume the box with the foward shift is a g52 5spd and the box with the top shift case is a 4spd from the earlier lux's here's a good page for boxes it may help you http://www.marlincrawler.com/htm/transm ... ission.htm

[bulldogy]

Also in the US they didnt come out with a forward shit R series box like here they only had top shift chain cases thats why on all the adaptors they say a top shift is needed.

[RUFF]

Pics hope it helps man.
Foward shift

Top shift

I'm assuming the top pic is R and bottom is G?

Do you have pics to show the difference in R and G type?

Top box is a G series the bottom box is a W series. Both 5 speeds. Bottom box was common in early solid axle toyota surfs.