EARLY HILUX 4SPD TO 5SPD

ODJ · Post by **ODJ** » Thu Feb 17, 2005 3:40 pm

Hi, I'm relatively new to the world of Hilux's and hav a question.
I've just purchased a 82 single cab 4wd Hilux which has been converted to Rover v8 power :lol:

.
It still has the original 4spd g-box connected using an adaptor of unknown origin. Due to not having a 5th gear it tends to consume petrol pretty rapidly with motorway driving. Does anybody know whether a later 5spd gearbox would be a major swap? Would the current 4spd adaptor fit the bellhousing of a 5spd or are they a very different in bolt pattern?
I've done a little research and found that the 82 Hilux did come with a 5spd, but this was in the USA. I've considered bigger tyres or "taller diff's but this would be relatively expensive compared to another g-box..
Has anyone done this conversion.?

SupraSurf · Post by **SupraSurf** » Fri Feb 18, 2005 10:52 am

If the gearbox is an alloy box with a steel sandwich then you can probably get a later G52 or W56 5 speed. If the box is an old cast iron beast then you are out of luck.

If you have the alloy box then you can create a 5 speed buy stealing the parts from a hiace 5 speed

De-Ranged · Post by **De-Ranged** » Wed Feb 23, 2005 6:50 pm

I"m doing this at the moment, but as usual I've gone overboard .... :roll:

I've dropped a 97 G52 five speed in and shoved a supra 2.8 upfront and I'm in the process of trying to fit the transfer case from the old 4 speed on to the end of my new 5 speed to give me double reduction

In my case I attacked the bellhousing from the G52 to make it fit the new motor (don't recomend doing this :evil:

well not without a bit more skills & time, than I've got!!)

If you don't change your box I've got one you can have as a spare

Cheers Reece

SupraSurf · Post by **SupraSurf** » Wed Feb 23, 2005 8:58 pm

I've got some brand new US made dual transfer adapters sitting in the garage for sale.... only $649 complete ready to go

De-Ranged · Post by **De-Ranged** » Thu Feb 24, 2005 4:33 pm

Is that you Mike?? or is this someone else I thought you'd been on this board for some time??

Anyway, back to the double trans adapter, I was working on the idea of machining one out of some alloy.... I haven't gotten round to it yet so I don't know just how hard this is gona be yet .... :lol:

considering how long it took to get this far and how little time I've got to put in to the toy you might just get a call

Cheers Reece

Oh I almost forgot I'll have an LPG set for a Rover 3.5L Classic for sale soon if your keen ODJ as a option

SupraSurf · Post by **SupraSurf** » Thu Feb 24, 2005 6:43 pm

De-Ranged wrote:Is that you Mike?? or is this someone else I thought you'd been on this board for some time??

Anyway, back to the double trans adapter, I was working on the idea of machining one out of some alloy.... I haven't gotten round to it yet so I don't know just how hard this is gona be yet .... considering how long it took to get this far and how little time I've got to put in to the toy you might just get a call

Cheers Reece

Oh I almost forgot I'll have an LPG set for a Rover 3.5L Classic for sale soon if your keen ODJ as a option

Yep still hangin around.
You'll find the machining for a dual a bit of a mission, you also have to make the internal spline to allow the second transfer to bolt up. Rather than machining try and cut the back off an old gearbox and front from xfercase and join em.

ODJ · Post by **ODJ** » Fri Feb 25, 2005 2:34 pm

Hey thanks for that SupraSurf.
I've just got the beast running properly :twisted:

and will have a go at the g-box.
You mentioned using later G52 or W56. does this mean it is a straight swap if i use the current bellhousing? Can I use the current transfer case or do I have to source another with the new box? :shock:

The LPG setup sounds interesting but have other things to do first.....
Do you know of any source of info for these gearbox conversions on the net - I haven't had any luck.

Cheers again.

SupraLux · Post by **SupraLux** » Sat Feb 26, 2005 9:59 pm

As a rule, the G52 came out in the Hilux utes and beam axle Surfs, and the W56 came out in the IFS surfs - circa mid-to-late 80's (ones with 2.4 turbo diesels mainly)

They both bolt up to the same bellhousing pattern and have the same basic dimensions, so can be interchanged at will. Driveshaft couplings are in the same place and have the same bolt patterns etc.

The difference is that the W56 T/C lever comes out of the T/C itself, so it makes taking the T/C off a simple job - whereas the G52 T/C lever comes out of the gearbox, and actuates the T/C via pushrods making seperating it and using it stand-alone for a dual setup just that little bit harder (but it is do-able)

Also, because of the different positions of the levers coming out of the case, a little trimming is required around the hole in the trans tunnel when swapping boxes over. Nothing major, takes 2 minutes with a pair of tin snips.

Hope that helps

Steve

De-Ranged · Post by **De-Ranged** » Sun Feb 27, 2005 8:18 am

You'll find the machining for a dual a bit of a mission, you also have to make the internal spline to allow the second transfer to bolt up. Rather than machining try and cut the back off an old gearbox and front from xfercase and join em.

I was sort of coming to the same idea I think it might just be a bit more work than I thought

hey tell me mike, are you GST reg'ed just curious to see what the easy option is going to cost :wink:

Cheers Reece

hosehustler · Post by **hosehustler** » Fri Dec 02, 2005 12:20 pm

SupraLux wrote:As a rule, the G52 came out in the Hilux utes and beam axle Surfs, and the W56 came out in the IFS surfs - circa mid-to-late 80's (ones with 2.4 turbo diesels mainly)

They both bolt up to the same bellhousing pattern and have the same basic dimensions, so can be interchanged at will. Driveshaft couplings are in the same place and have the same bolt patterns etc.

The difference is that the W56 T/C lever comes out of the T/C itself, so it makes taking the T/C off a simple job - whereas the G52 T/C lever comes out of the gearbox, and actuates the T/C via pushrods making seperating it and using it stand-alone for a dual setup just that little bit harder (but it is do-able)

Also, because of the different positions of the levers coming out of the case, a little trimming is required around the hole in the trans tunnel when swapping boxes over. Nothing major, takes 2 minutes with a pair of tin snips.

Hope that helps

Steve

Hi Steve, Ihave brought a IFS gearbox & transfercase (W56), plan on putting it in tomorrow, apart from the trimming around the floor, does the cross member ect line up exactly as the G52 does :?:

and do you have an IFS interior boot/sorround for inside the truck in your shed as this would tidy mine up when finished

SupraLux · Post by **SupraLux** » Fri Dec 02, 2005 7:54 pm

Hi Tim... all you need to do is trim the trans tunnel and bolt a bit of steel over the hole left at the other end (of only to stop the water coming in

)

The crossmember and driveshafts all bolt up perfectly.

Its a simple case of swapping the bellhousings, and bolting it in.

Sorry, the only IFS gumboot and leather sock I have are fitted to my 'lux, and thats where they are staying for now

Not sure what to do with the old girl tho... don't wanna wreck it out, but can't really justify the time to rebuild it...

Steve

tomsoffroad · Post by **tomsoffroad** » Sun Dec 04, 2005 12:49 am

Not sure what to do with the old girl tho... don't wanna wreck it out, but can't really justify the time to rebuild it...

Steve

Know the feeling. :wink:

De-Ranged · Post by **De-Ranged** » Sun Dec 04, 2005 11:22 am

Not sure what to do with the old girl tho... don't wanna wreck it out, but can't really justify the time to rebuild it...

I know that feeling so well... one day I'll get time :roll:

Cheers Reece