Outer Limits 4x4 Board

Hi lads

Looking at fitting an R150 gearbox and transfer into my LN106 hilux. The G52 has packed it in and i need something stronger.

What mods need to be done to fit the box in? Will my single piece tailshaft bolt straight on? Are the mounting points on the cross member the same? Does the 2.4l surf bell housing bolt onto the box and onto the engine without any hassles? Do I have to mod the interior for the stubby lever?

Any info would be a great help.

Hey bud I have a LN106 turbo and after 4 G52's it was time to put in something stronger.

I just did this conversion and its a piece of p!ss! I believe its money well spent them G52 boxes cant handle torque from slower revving diesels i have seen them last ages behind a holden V8, I strongly suggest you get a R151 instead of a R150 1st gear in the R151 is 4.3 compared to 3.7 in the R150 and is beautiful for taking off with taller tires. I got my R151 from a 2004 factury turbo diesel.
I went for the R151 swap cause marks are too expensive for a dyna box and their 5.15 1st gear is too tall for what i do

Get yourself a bellhousing and drivers side engine stay (the plate that bolts onto the side of the engine to the lower part of the bellhousing cause the one from the 106 wont bolt up) from a LN130 surf wich had the 2lt engine this will bolt up to your 106 and the R151
Go to marks 4x4 and (yes marks) and get yourself an adaptor plate to mount the R151 box to your original gear driven transfercase costs $575 You have to do a dry run with the adaptor as one of the bolts that mount the transfer wont clear the back of the R151 box only requires a small amount of grinding to make it clear

No lengthening of shafts crossemebers etc all standard if your one piece fits now it shoud still fit

Also the seal from the transfercase to the gearbox shaft that comes in marks kit does not fit and after ENDLESS calls they just kept hanging up, and left the phone on the hook. Love your work ben from marks 4X4. I just went to bearing wholesalers and got a different seal product no. 401045P that fits no problemo

Doing it this way it bolted straight in! Only thing is that your 4x4 selector need to be lenghtened 16mm cause the top shift on the R151 box is higher and the 4x4 shifter from the R series box is different and will not fit

Great news is that by keeping your geardriven tc you can put twins in later on rather than using the chaindriven case

This is what it cost me
LN 130 bellhousing $150
Reco R151 in plastic $1450 you dont have to get a reco there are some cheap second hand boxes around.
Marks 4x4 adaptor plate $575

Total $2115

Lux now drives fantastic no need to ride the clutch for takeoff and no more need for worry about blowing boxes miles away from home!

Doubz wrote: Go to marks 4x4 and (yes marks) and get yourself an adaptor plate to mount the R151 box to your original gear driven transfercase costs $575 You have to do a dry run with the adaptor as one of the bolts that mount the transfer wont clear the back of the R151 box only requires a small amount of grinding to make it clear

No lengthening of shafts crossemebers etc all standard if your one piece fits now it shoud still fit

Also the seal from the transfercase to the gearbox shaft that comes in marks kit does not fit and after ENDLESS calls they just kept hanging up, and left the phone on the hook. Love your work ben from marks 4X4. I just went to bearing wholesalers and got a different seal product no. 401045P that fits no problemo

Doing it this way it bolted straight in! Only thing is that your 4x4 selector need to be lenghtened 16mm cause the top shift on the R151 box is higher and the 4x4 shifter from the R series box is different and will not fit

Or you could buy the trail gear adaptor for $24 more which works 100% off the shelf

http://locktup4x4.com.au/product/2b10bd ... 2fadf.aspx

What about the clutch? is it all the same?

Get the trailgear adaptor- My marks adaptor is a pice of shit. Leaks like a sieve- NONE of the supplied seals suit the applications- I fixed the seal on the adaptor plate into the input shaft on the transfer (after it filled the cavity with the transfer cases oil!) and then discovered that the new coupler they supply doesnt even seal on the back of the gearbox, which allows all the oil in the gearbox to flow into the cavity!

Coincidently- R151's explode when they run dry of oil!

im running an R150 (from an aussie spec TD lux- the Lux's ran R150F's, the Prado TD's ran R151F's, Surf KZN130's run R151F, D4D Lux's run an uprated R150, but it is missing a sensor the 1KZ motor needs) and ive found the slightly taller first gear is good- I dont tend to turn my tires to smoke off the line with a tromp any more!

Courtesy of marks products, I now have to monitor my gearbox oil weekly, have a transfer case that has about 3L TOO MUCH oil in it, and have to pull the transfer off AGAIN to try and rectify it.

Put a bypass line between the two filler plugs. Very common and an easy fix. You can buy the kit off Ebay otherwise Sunshine State Toyota sells them.

I made mine myself by drilling out the filler plugs and tapping a bsp thread in them and join with oil grade tubeing.


http://cgi.ebay.com.au/TOYOTA-HILUX-GEA ... .m20.l1116

Clutch was all good using the LN130 housing there was no need to extend the input shaft.

I looked up the trailgear adaptor but the bloke on the phone reckoned that the coupler that comes in the kit does not suit the 21 tooth input shaft on our gear driver transfercases you have to change the shaft to a 23 tooth and i couldnt be bothered. Yeah he reckoned the kit was built for the V6 to be able to use the gear driven transfercase and would break the 21 tooth shaft i doubt my old diesel will come close to breaking it!!

As for marks adaptor I was concerened about the seals especially seeing as they supplied me with the wrong ones!!!

Ill just have to keep an eye on the oil levels if anyone finds a fix for this let me know

Doubz wrote:I looked up the trailgear adaptor but the bloke on the phone reckoned that the coupler that comes in the kit does not suit the 21 tooth input shaft on our gear driver transfercases you have to change the shaft to a 23 tooth and i couldnt be bothered. Yeah he reckoned the kit was built for the V6 to be able to use the gear driven transfercase and would break the 21 tooth shaft i doubt my old diesel will come close to breaking it!!

this is true.
So you use it for a good excuse to buy transfer gears and get the 23 spline ones
Or you can just buy the 23 spline input shaft (about half the cost of gears anyway).
Depends I guess I you want the added cost or not. You still have to mod the shifter of course.

This is what my father did for his hilux, and it did cost a little bit, however it was as easy as falling off a log. This came in at around $1200 total, and it cost us $900 for the R151 box. If we could sell the left over G52 and chain transfer could re-coup some money. Its not too bad a cost for an excellent end result.

Willy Hilux wrote:Put a bypass line between the two filler plugs. Very common and an easy fix. You can buy the kit off Ebay otherwise Sunshine State Toyota sells them.

I made mine myself by drilling out the filler plugs and tapping a bsp thread in them and join with oil grade tubeing.


http://cgi.ebay.com.au/TOYOTA-HILUX-GEA ... .m20.l1116

Personally i consider this a bandaid to a problem, not a fix- I shouldnt have to make it so my oil dribbles back into the gearbox via a bloody pipe- the oil should just NOT pass from Gearbox to trasfer.

Its pretty shit that you pay $600+ for a product, and the slack bastards cant even give you the right seals. The seal i got with my adaptor plate for the transfer input fell clean through the plate when i test fitted it- it was that loose!

ferrit wrote:

Willy Hilux wrote:Put a bypass line between the two filler plugs. Very common and an easy fix. You can buy the kit off Ebay otherwise Sunshine State Toyota sells them.

I made mine myself by drilling out the filler plugs and tapping a bsp thread in them and join with oil grade tubeing.


http://cgi.ebay.com.au/TOYOTA-HILUX-GEA ... .m20.l1116

Personally i consider this a bandaid to a problem, not a fix- I shouldnt have to make it so my oil dribbles back into the gearbox via a bloody pipe- the oil should just NOT pass from Gearbox to trasfer.

Its pretty shit that you pay $600+ for a product, and the slack bastards cant even give you the right seals. The seal i got with my adaptor plate for the transfer input fell clean through the plate when i test fitted it- it was that loose!

I think it is a good idea to have this balance hose. If you were doing a long trip and ya seal started bypassing it could be too late before you pickup on the leak.

I'm not saying anything about the poor product - that would shit me off too. But I think the hose is apeace of mind cheap idea.

Yep its official. New gearbox set u has done 1200km..............

AND IT LEAKS!!!!!!!

Dont know whether its from the transfer or the box yet, Im tipping its the box!!
I dont remember but is the coupling hollow or was it sealed from end to end? Cause the coupling goes from the inside of the box into the cavity and then onto the input shsft of the transfercase.
If the coupler is hollow oil will make its way into the cavity no problem I dont care how good the machine job is oil will pass through the inside of the coupling. Ill have to find a way to seal it up, OR its another "MARKS SPECIAL" and his given us the wrong seals again! Might want to get the verniers out measure up the surfaces and go to bearing wholesalers for some new seals

My thoughts anyway and then.....

I fell off my KTM n broke my arm so i wont be able to do much to the lux for a while!!!! I blame MARK!!!!

will be from the box- Check your gear level oil- it takes about 2000kms to pump your gearbox 3/4 dry.

The coupler is hollow- the only solution i can think of is de-grease the coupler and the shaft, and smear the whole mess with RTV silicone to try and seal it.

Most of the couplers have a small undercut or champher on the front of each end of the internal spline find a small 1/16th oring same dia and fit it to bothe ends and no leak Also the RTV is a good idea use one for automatic transmissions for some reason they stick better and faster.

Pretty sure the OD of the coupler is 38mm or supposed to be the same that came from factory.

Hi guys im just about to put a 1ggte in my 84 hilux and i am looking for a gearbox upgrade whilst all the old stuff is out. I was planning to get a r150 or something out of an 80's/90's surf. Will this gearbox and transfer bolt in in place of my old g52? I know the chain driven transfer is a little weaker but is that the only difference? Will the shifters and that still come up in the same place and will the unis still bolt up ok?

Cheers

Brad

Must renig my box has not leaked a drop yet

And my wrist is back now have a YZ450 and a 500 suzuki quad

Ferrit machined his adaptor plate to fit the seal supplied with the kit.

The seal supplied with the kit is wrong for aussie 21 input tooth transfercases and is fine for the 23 tooth USA transfercase

Marks 4X4

Oops my bad

Cheers

Doubz