26 Hume Reserve Court, Nth. Geelong, 3215 Phone: (03) Fax: (03) DUAL RANGE HIGH SPEED INSTALLATION MANUAL. for

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1 26 Hume Reserve Court, Nth. Geelong, 3215 Phone: (03) Fax: (03) GEARLESS CENTRE DIFFERENTIAL FULL-TIME 4X4 TRANSFER CASE CONVERSION DUAL RANGE HIGH SPEED INSTALLATION MANUAL for TOYOTA LANDCRUISER HZJ 105 & LDJ 70 SERIES See our website

2 TOYOTA 105 & 70 series Dual Range High Speed GCD Manual 1 8 FIRST REMOVE TRANSFER CASE FROM VEHICLE DISASSEMBLY 3 1. REMOVE SPEEDO DRIVE GEAR FROM REAR EXTENSION HOUSING. 2. REMOVE TRANSFER INDICATOR SWITCH 3. REMOVE SCREW PLUGS, SPRINGS AND BALLS (a) Using a torx wrench (T40), remove the 4 screw plugs. (b) Use a magnetic finger to remove the 2 springs and balls. 9,10 Note: Retain these items for reassembly 4. 4 REMOVE REAR OUTPUT SHAFT COMPANION FLANGE (a) Using a chisel and hammer, unstake the locknut. (b) Using SST to hold flange, remove the nut and O-ring 11 NOTE: O-ring should withdraw with flange 5 5. REMOVE FRONT EXTENSION HOUSING Remove 6 bolts and carefully ease off front extension housing. 6. REMOVE FRONT DRIVE CLUTCH SLEEVE, NO.2 SHIFT FORK AND FRONT DRIVE SHIFT FORK SHAFT 7. REMOVE REAR EXTENSION HOUSING Remove the 9 bolts and carefully ease off the rear extension housing. 8. REMOVE SPACER FROM REAR OUTPUT SHAFT Note: Not required for GCD conversion. 9. REMOVE ADJUSTING SHIMS FROM IDLER GEAR TAPER ROLLER BEARING Note: Retain shims for reassembly 12a 12b 10. REMOVE ADJUSTING SHIMS FROM OUTPUT SHAFT REAR TAPER ROLLER BEARING Note: Retain shims for reassembly REMOVE INPUT SHAFT REAR CASE COVER Remove the 5 bolts, tap the case cover and remove it. 12. SEPARATE FRONT CASE AND REAR CASE (a) Using a snap ring expander, remove the outer snap ring from the rear case ( input shaft back bearing) (b) Remove the 8 bolts and carefully ease off the rear case REMOVE IDLER GEAR ASSEMBLY, NO. 1 SHIFT FORK WITH HIGH AND LOW SHIFT FORK SHAFT (a) Using a pin punch drive out the slotted spring pin from the No1 shift fork. (b) Remove the No1 shift fork and the high and low shift fork shaft. 1 13

3 2 5 ASSEMBLY OUTPUT SHAFT DISASSEMBLY NOTE: High and low gears, bearings etc are removed from the Toyota output shaft and re-assembled onto the GCD hollow output shaft supplied in the GCD kit. Inspect bearings and replace if necessary REMOVE FRONT DRIVE GEAR (a) Remove snap ring. (b) Press off front drive gear. NOTE This gear is assembled onto the GCD Front Drive Thru Shaft 3. PRESS OFF FRONT TAPER ROLLER BEARING. 4. REMOVE HIGH SPEED GEAR, SYNCHRONISER RING, & NEEDLE ROLLER BEARING. 5. PRESS OFF REAR BEARING & REMOVE LOW GEAR 6. REMOVE CLUTCH HUB AND HIGH AND LOW HUB SLEEVE (a) Using 2 screwdrivers of same size drive out the clutch hub snap ring. (b) Slide off hub sleeve. (c) Press off clutch hub. 6a 6b ASSEMBLY OF GCD OUTPUT SHAFT COMPONENTS 7 7. Install clutch hub onto GCD output shaft. NOTE: Be sure hub is correctly oriented before installing. 8. Install snap ring. 9. Push high and low hub sleeve assembly onto shaft. ( chamfer to front) Install needle roller bearing, slide on low speed gear. 11. Press on rear taper roller bearing.( No. 3890) 12. Install needle roller bearing, spacer, synchroniser ring and slide on high speed gear. 13. Press on front taper roller bearing (No. 3590) 8 11 PREPARATION OF GCD THRU SHAFT (a) (b) (c) Install front drive gear piece onto GCD front drive Thru-Shaft. Install snap ring onto Thru-Shaft. (supplied) Insert needle roller bearing (supplied) into GCD Thru- shaft. 2

4 1 8 COMPONENT ASSEMBLY INTO TRANSFER CASE 1. REPLACE OUTPUT SHAFT FRONT BEARING CUP ( NO ) (NOT NECESSARY FOR NEW VEHICLE) 2. INSTALL FRONT DRIVE SHIFT FORK SHAFT NOTE: After installing the front drive fork shaft push home straight pin INSTALL NO.1 SHIFT FORK AND HIGH AND LOW FORK SHAFT. NOTE: Set shift inner lever into the fork head part of the No.1 shift fork securely INSTALL IDLER GEAR ASSY INTO FRONT CASE 5. INSTALL GCD REAR OUTPUT SHAFT ASSEMBLY 10 NOTE: After assembling components into front case, the slotted pin should be driven back into the No1 fork shaft with pin punch inserted through case. NOTE: When re-assembling housing components apply a 3mm bead of silicone sealant as shown. Part No , Loctite Superflex red 59630, or Permatex High Temp red RTV Silicone , INSTALL REAR CASE ONTO FRONT CASE AND TAP HOME. Torque up 8 bolts to 37Nm. (27ft.lbf.) 7. INSTALL SNAP RING ONTO REAR OF INPUT SHAFT. 8. INSTALL CASE COVER Torque up 5 bolts to: 37Nm (27ft.lbf.) 9. INSTALL IDLER AND OUTPUT BEARING CUPS. 10. INSTALL IDLER GEAR ADJUSTING SHIMS. Measure and confirm preload is within following specs. Thickness A mm ( in.) SET REAR OUTPUT SHAFT PRELOAD Measure distance as shown from the case to the bearing cup and add the required preload as follows; 7 Thickness Dim B mm ( in. If not select a shim from the kit supplied to create correct preload. 12. INSTALL GCD REAR EXTENSION HOUSING. Torque up 9 bolts to 37Nm. (27ft.lbf.) 13. ASSEMBLE GCD HEMI ASSY AND INSTALL INTO GCD REAR EXTENSION HOUSING. (a) Carefully push hemi into the GCD rear extension housing and slide onto splines of the Output Shaft. 14. ROTATE GCD SHAFT TO CONFIRM TURNING TORQUE. With transfer case in N rotate shaft to check preload with no end play. 3 13

5 INSTALL FRONT EXTENSION HOUSING (a) Install front drive clutch sleeve and No.2 shift fork NB. Large chamfer goes to front (b) Insert GCD Thru- Shaft into main output shaft. Slide splines into GCD hemi assembly (c) Push front extension housing into position. Torque up 6 bolts to: 37Nm ( 27ft.lbf.). 16 Rotate INSTALL GCD SPEEDO DRIVE HOUSING ONTO REAR EXTENSION HOUSING. (a) Place gasket (supplied) onto Speedo Housing. (b) Place Speedo Drive housing onto rear output shaft and slide the bearing home till it seats against the shaft shoulder. NOTE: Speedo Drive housing is rotated 180 deg. from normal position in order to clear fuel tank. Torque up 6 bolts to 37Nm.(24ft.lbf.) ( 6 Flange head bolts supplied) INSERT 7 MM SPACER ONTO REAR OUTPUT SHAFT. ( Chamfer goes towards bearing.) 18. INSTALL OUTPUT SHAFT COMPANION FLANGE ( With speedo drive gear fitted) 19. INSTALL O-RING ONTO REAR OUTPUT SHAFT. 20. INSTALL, TORQUE AND STAKE FLANGE NUT Torque nut to 127Nm (94ft.lbf.) 21. INSTALL SPEEDO DRIVE GEAR 22. INSTALL TRANSFER INDICATOR SWITCH. 23. INSTALL 4 SCREWS, PLUGS, 2 SPRINGS AND BALLS 24. RE-INSTALL TRANSFER CASE INTO VEHICLE. 25. RE-CONNECT FRONT PROPELLOR SHAFT. 26. INSTALL SHORTENED REAR PROPELLOR SHAFT. Shaft is shortened by 120mm from standard length. 27. CUT SPEEDO DRIVE WIRE AND LENGTHEN WITH EXTENSION WIRING ( SUPPLIED IN KIT) 28. RE-CONNECT ALL WIRING AND HOSES. 29. FILL WITH OIL AS PER TOYOTA SPECIFICATIONS FOR TRANSFER CASE. Case will now take approx. 2 litres of oil. 4 25,26

6 GCD OPERATIONAL TEST The GCD is designed to un-lock and re-lock the common drive to front and rear axles when one axle attempts to overdrive the other axle during cornering. NOTE: the above de-coupling action operates in both forward and reverse gears. DE-COUPLE SIMULATION 1. With the vehicle chocked for safety at the rear wheels raise the FRONT axle wheels off the ground. 2. LIGHTLY try to rotate the prop shaft of the raised axle both clockwise and anticlockwise. OBSERVATION: The transfer case common axle drive should feel solid and not able to be turned. 3. NOW FIRMLY rotate the driveshaft of the raised axle and the un-locking can be felt as the prop shaft breaks out and spins freely. Reverse the rotation of the raised axle prop-shaft and after first re- locking, the shaft will un-lock and spin freely in the other direction. 4. Lower the raised axle and repeat these steps to check the REAR axle. FOR OPTIMUM PERFORMANCE NOTE: (a) It is very important that all 4 wheels be of matching diameter for optimum traction and performance. (b) During cornering, the GCD may be heard indexing as it un-locks and re-locks. This is quite normal. GCD KIT PARTS LIST x Central Driver Hemi Assembly x Front Drive Thru-Shaft x Output Shaft Main x Rear Extension Housing x 7mm Spacer x Speedo Drive Housing x Bearing Speedo Drive Housing (6207) x Circlip ( ) x Oil Seal Rear ( ) x Bolts Flange Head (M10 x 1.5 x 40) x Bearing Rear output front ( x Bearing Rear output Rear (3890) x Gasket Speedo Drive Housing (Special) x Warning Sticker - Dashboard x Installation Manual 5 26 Hume Reserve Court, Nth Geelong Phone: (03) Fax: (03)

7 High Range Gear Needle Roller (GD ) (GD ) (GD ) (GD ) (GD ) Clutch Hub 26 Hume Reserve Court, Nth Geelong Phone: (03) Fax: (03) Low Range Gear TOYOTA HZJ 105 & LDJ-70 SERIES COMPONENT ASSEMBLY GEARLESS CENTRE DIFFERENTIAL - Dual Range Conversion

26 Hume Reserve Court, Nth. Geelong, 3215 Phone: (03) Fax: (03) INSTALLATION MANUAL. for

26 Hume Reserve Court, Nth. Geelong, 3215 Phone: (03) Fax: (03) INSTALLATION MANUAL. for 26 Hume Reserve Court, Nth. Geelong, 3215 Phone: (03) 5272 2844 Fax: (03) 5272 2633 GEARLESS CENTRE DIFFERENTIAL FULL-TIME 4X4 TRANSFER CASE CONVERSION DEDICATED LOW RANGE INSTALLATION MANUAL for TOYOTA

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