Changing Transfer Cases

[Andrew_C]

I have a mate who looks like he has done some damage to his transfer case in his 89 75 series diesel. I have another mate who has a 5 speed gear box and transfer out of a 60 petrol. Will the transfer from the 60 fit the diesel and how hard is it to swap them over,

Can somebody give me a brief run down of the process. I have done GQ boxes at home and also hiluxes so im willing to give it a go over a few cans.

Thanks

[bad_religion_au]

it's easier to swap the gearbox and Tcase at once... unbolt the 4 bolts from the bellhousing, unbolt the shifters, and the driveshafts, and swap.

the cases are the same T-case, although i think the 75 series will have a lower low range, so he might not go as slow in lowrange when the swap is done

[Andrew_C]

So are you saying swap both the gear box and transfer, I had a feeling somewhere the gearboxes had different ratios, But 4 bolts on the bell housing and dropping the whole lot doesn't sound too hard. Are they hard to realign the clutch and get back together.

[bad_religion_au]

So are you saying swap both the gear box and transfer, I had a feeling somewhere the gearboxes had different ratios, But 4 bolts on the bell housing and dropping the whole lot doesn't sound too hard. Are they hard to realign the clutch and get back together.

realignment isn't a huge issue, takes some wiggling... easiest way i've found is to suspend the gearbox by an engine crain or something similar, and wiggle it in.

the gearboxes are the same ratios... all H55f's, the t cases differ in ratio IF i have my change over dates correct. but that won't make it inoperable.

oh and you gotta undo the 4 bolts so the crossmember comes off the chassis (mind blank, 4 speeds don't necissarily have this). probably have to unbolt the crossmember off the boxs and swap them, as i imagine the 75 series one would be different.

and one last thing you might run into... the driveshaft flanges may be different... i don't know the change over dates... easy fix tho, separate the shafts, and use the female end (short end) from the 60 series and bolt that end on the tcase, then use the long sections from the 75 series. the slip yolk splines are the same so thats not an issue.