60 series boxs to a 45

[nottie]

OK guys just wondering if i can bolt up a 60 series 5 speed gearbox and transfer to a 2F in a 45 series. I think the truck is something like a early 70s and has a 4 speed in it at the moment with a dodgy old split case .
Cheers Nottie

[RAY185]

Yeah all good, I did it to my 40. Only issue will be that you cant put the transfer case handbrake from the 40 onto the 60 case. Rear wheel handbrake options are later model 40 rear brakes and cable to suit or 60 rear brakes and cable to suit. I went 60 rear brakes with mine. Then its just getting the propshaft and tailshaft to suit and you're done.

Oh then theres just the little issue of the sticks being in a different position. I cut the trans cover to suit and bolted the 60 trans cover onto the 40 cover to keep it semi neat.

Hows that grill?

[nottie]

Cheers for that Ray
Yeah was thinking of maybe a disc handbrake on the output of the transfer . The grill is still in the shed as i am selling the buggy. Still in good nik
So the 60 box bolts to the 2F and i gather ill need to make a crossmember. Also they are all hydro clutches arnt they? if so will the standed clutch master run the slave cylinder on the 60 box (as in i can just connect the line from the 40 straight to the 60 slave cylinder)
Are the fly wheels diffrent? and if i change the diff pinions to a late 60 fine spline is there any factory shaft that anyone knows about that will bolt in or will i have to get some 60 ones custom lengthed?
Cheers

[pcman]

ive just done this in my fj45 troopy

was a pain i really reccomend to remove the engine bolt it all together on the floor and refit as the main chassi crossmember behind the transfer means you have less than 20mm of play to get the gearbox in VERY TIGHT

you will not fit any transfer case handbrake without removing the crossmember aswell


clutches are the same bellhousing is the same i just reused my 40 series clutch slave well then replaced it cause it wouldnt operate the new clutch i fitted


for roughly the same cost a 60 diff with the spring perches moved is a easy fitup to the rear and they all have handbrake on the rear diff andas a bonus there a tad wider

[nottie]

Cheers Pcman. Ive just finished putting a 60 front diff in and was thinking bout the rear as it has 2inch wheel spacers on it so going to a full 60 is probly the best idea on the handbrake path. When you did this did you just modifie a 60 handbrake cable?

[RAY185]

Cheers Pcman. Ive just finished putting a 60 front diff in and was thinking bout the rear as it has 2inch wheel spacers on it so going to a full 60 is probly the best idea on the handbrake path. When you did this did you just modifie a 60 handbrake cable?

You'd be crazy not to fit the 60 rear diff if you've done the front. The front is the hard one with the drivers side perch, rear will be a walk in the park for you. Then you just need to sort the handbrake cable itself. Is your lever on the floor or a pull out from dash job?

As pcman said, same clutch, flywheel etc, it all bolts up. Mine went in easy since I had a body lift. Would be a pain getting it in there with no body lift clearance wise.

They are all hydraulic and the slave cylinders are the same as the 40 for the early 60. Different slave for the later 60 (post 84).

As for a crossmember, I just made up a heavy bashplate, made a bracket off the transfer case and used a falcon gearbox mount between them. No probs so far, been in for 2 yrs plus.

Not sure how you'll go for tailshafts as mine is a shorty. I ended up using a 60 rear shaft (I moved the rear diff back) and got a 60 front shaft shortened to suit (double cardinal).

[nottie]

yeah as far as the front diff went i did it the other way around and moved the spring hangers out on the chassis end and it drives alot more stable and seems to be very stable off road plus the fact that who ever had this truck in the past wasnt real great with the stick welder when they did a shackle reversal on it. It flexs like hell with the spring packs i came up with.
I think there is a plan in the works to do the rear but need to get the transfer sorted first as it keeps popping out of H2. Hence my idea of putting a 5 speed in it at the same time and running the better transfer.
Oh by the way this isnt my truck it is a mates that lets me do what i like on it for him as long as we allways try to do things on the cheap.
( i want to do a windsor v8 c4 and 60 case but he wont be up for that)
Yeah she is body lifted so that should make life easier from what you guys have said.
Cheers for the info again guys
Nottie

[pcman]

well ive actually been lazy and havnt fittted the rear diff yet so i just leave it in low 1st LOL

im also going disc rear brake so cable will be different but i beleve the 75 troopy handbrake cable would be long enough

a stock 60 one wont be long enough

i posted up a thread asking about a handbrake cable but noone gave me a definat answer iirc

[nottie]

If going rear discs what caliper are you planning on using?
I did this on my buggy with a rear 60 diff and used GQ discs as they went straight over the hub and used 60 series front calipers but the transfer case i run in the buggy doesnt have a brake drum so i have no handbrake.
I would like to do discs on the rear of my mates truck but unsure what calipers to use. Wonder if 80 series calipers use a handbrake cable on them?