Outer Limits 4x4 Board

car is a 1990 hilux 2.8 3L motor with a g52 box apparently,

ok so i picked up a second hand gearbox, as i stripeed the teeth of one of the gears in mine,
looking at the back of both of the gearboxes they look identical, but i ran into a bit of a problem getting then together,
excuse my description as i dont know any fancy names for parts,

now, there is a male spline that comes out of the gearbox, and a male spline that comes out of the transfer case, and a female piece that slips over both of them to join them, now the female peice that i have (that came out of my gear box) fits on to my transfer but not on to the spline that comes out of the new gearbox.

my gear box has 21 teeth and the new one has 26 teeth on the spline,
so my old box had less, larger teeth, and the new box has smaller size but more teeth, if that makes sense.

from what i can tell they are (very close to if not exactly) the same diameter about 27mm to the outside of the teeth. I am not sure what year the other box was out of.

is there another peice i can get to join them? any way of changing the spline from the new gearbox to the one from my old box? or is this box a no go?

The bit that goes in the back of the box (Not the transfer case part tho) are they both internal spline in the box or is the 26 spline on the outside. Also by any chance did the box come out of a surf or 4runner.

both the splines are on the outside, (I think) sorry for the dogdy photos, hope they answer your question,

THis is the new box, looks exactly the same as the old one, other than the spline coming out the back. not sure what its out of or what year??



This is the joiner piece,



And this is my original box with the joiner piece attatched.





Does anyone have any idea if there is anyway this can work, or is this just not going to happen?

Thanks

anyone?

Should be able to use your old coupler and your original extension housings as like i thought the new box you have has come from something with a chain driven case so the extension housing that was on the new box will not mate up with the holes on the geardriven case off your old box rigth? If i could find my hilux manual i'd be able to be 100% sure on this

ok, so how do i mate up the two splines?

yes, you are right in that the extension housings are different and wont mate up to my transfer. but thats not the problem,

the problem is the splines have a different amount of teeth on them to my coupling (im guessing the coupling is the part that slips over the two splines to join them)

Thanks heaps for the help so far

so that first pic that output shaft spline is diffrent to you original box i would have thought if they are both g52 transmissions they only difference would have been the coupler (yeah the part with the internal splines each end of it)

Thats what i thought when i bought it, they both look exactly the same, only difference i could pick was (and the guy i bought it off told me this) that i would have to swap the extension housing,

how ever the output shaft from my gearbox has 21 teeth the output shaft on the new box has 26 teeth.... and i cant get the coupling to fit..... as it has the internal teeth to suit the 21 tooth spline...

I really appreciate your help/advice on this!!

zero wrote:

So your saying that this spline count is diffrent on your box to the new one just a silly suggestion you've tried the coupler both ways

I think the splines are the same for all modles with gear driven transfurs. You havnt got a late gearbox that goes on to a chain drive transfur do some research.

^ huh?

yeah ive tried the coupling both ways.
on my original box it is the same tooth count as the transfer (the coupling is the same at both ends)

Hi
This mite be no help,Buti have a 94 hilux with a chain driven transfer,So if you have no luck with the gearbox i mite be interested in the box as mine is ready to shit it self as well..Please give me a call if interested in selling or do a trade ??
Cheers Jon

ok will keep it in mind, f i have no luck will let yuu know

Hey
Have you got your gear box sorted? I just got my self a reco gear box out of a 1990 4wd 2.8 diesel hilux,And it looks like its going to be wrong,As mine is chain driven transfer.Have you found out if yours was a chain driven transfer?? If it is we mite be able to do a swap???

Your car's original G52 gearbox had a gear driven transfer case mounted and 21 spline output (you know that already).

You bought yourself a G52 gearbox that had a chain driven t/f case mounted and as you are finding it's not a direct swap.

One option that may be available is to contact Marks Adaptors because they do a kit for nearly all of this job.

Your spare gearbox's transfer case adapter housing will be different to your car's original gearbox (even though they're called the same). You can do what you are doing atm, ie trying to swap the necessary bits from one to the other which will probably be a lot of work, or get the kit from Mark's that includes an adapter plate and coupler to mate a 26 spline box output to a 21 spline t/f case input and do a bit of work too. About $600 I think. The transfer case adapter on the spare gearbox that you have will need a bit of grinding to allow your orig gear driven case to fit on with the new adapter plate. Also, if you go this way, the shift forks from the transfer case will now sit back about 16mm more than before meaning that the tf case gearstick won't reach them. So you need to lengthen those.

Maybe easier to just find a chain driven tf case for your spare box?

Mate if have no luck I'll change the output shafts over between the boxes.

Cheers

Russ