26 Hume Reserve Court, Nth. Geelong, 3215 Phone: (03) Fax: (03) 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 DEDICATED LOW RANGE INSTALLATION MANUAL for TOYOTA LANDCRUISER VDJ - 70 SERIES See our website service@gearingdynamics.com

2 Toyota 70 series Low Range GCD Manual 1 DISASSEMBLY WITH TRANSFER CASE REMOVED FROM VEHICLE REMOVE SPEEDO DRIVE GEAR FROM REAR EXTENSION HOUSING. 2. REMOVE 2 SCREW PLUGS, SPRINGS AND BALLS (a) Using a torx wrench (T40), remove the 2 screw plugs as shown (b) Extract balls bearings with a magnet. (c) Replace 2 screw plugs after applying sealant. 8 Note: Springs and balls are not required for GCD use REMOVE REAR OUTPUT SHAFT COMPANION FLANGE (a) Using a chisel and hammer, un-stake the locknut. (b) Using SST to hold flange, remove the nut and O-ring 4 5,6 Note: O-Ring should withdraw with flange 4. REMOVE FRONT EXTENSION HOUSING (a) Remove 6 bolts and carefully ease off front extension housing. 5. REMOVE DRIVE CLUTCH HUB FROM FRONT SHAFT (a) Using a snap ring expander, remove the snap ring. (b) Using a puller, remove the drive clutch hub. 6. REMOVE FRONT OUTPUT SHAFT FROM HOUSING (a) Using a plastic hammer tap the shaft out of the bearing 7. REMOVE FRONT DRIVE CLUTCH SLEEVE, NO.2 SHIFT FORK AND FRONT DRIVE SHIFT FORK SHAFT All these items can be discarded as they are not required with the GCD. 8. REMOVE REAR EXTENSION HOUSING Remove the 9 bolts and carefully ease off the rear extension housing. 9. REMOVE SPACER FROM REAR SHAFT Note: Retain spacer for reassembly with the GCD 9 10, REMOVE ADJUSTING SHIMS FROM IDLER GEAR TAPER ROLLER BEARING Note: Retain shims for reassembly 11. REMOVE ADJUSTING SHIMS FROM OUTPUT SHAFT TAPER ROLLER BEARING Note: Retain shims for reassembly. 12. REMOVE INPUT SHAFT REAR CASE COVER Remove the 5 bolts, tap the case cover and remove it. 1

13 14 13. SEPARATE FRONT CASE AND REAR CASE (a) Using a snap ring expander, remove the snap ring from the rear case ( input shaft bearing) (b) Remove the 8 bolts.

3 SEPARATE FRONT CASE AND REAR CASE (a) Using a snap ring expander, remove the snap ring from the rear case ( input shaft bearing) (b) Remove the 8 bolts. (c) Using plastic Hammer, tap the rear case and gently separate it from the front case. 14. REMOVE IDLER GEAR ASSEMBLY, NO. 1 SHIFT FORK WITH HIGH AND LOW SHIFT FORK SHAFT Remove the idler gear assembly, output shaft assembly, No. 1 shift fork with the high and low fork shaft from the front case. Note: Only idler gear required with GCD assembly. Discard other items REMOVE SHIFT OUTER LEVER AND SHIFT INNER LEVER SHAFT (a) Remove the nut and washer from the shift outer lever. (b) Using a pin punch and hammer drive out the lever lock pin. (c) Remove the shift outer lever and shift inner lever shaft. Note: Not required for use with the GCD 16. REMOVE SHIFT LEVER OUTER OIL SEAL (a) Using a screwdriver, prise out the oil seal. 18 Note: Not required for use with the GCD 17. INSTALL 27mm WELCH PLUG INTO SHIFT LEVER HOLE (b) Using a socket, install Welch Plug ( 27mm supplied) to block off shift lever opening. 18. REMOVE OUTPUT SHAFT FRONT BEARING OUTER RACE IN FRONT CASE (a) Remove the original bearing cup from the front case. Note: Not required for use with the GCD NEW BEARING SUPPLIED WITH GCD KIT 1 ASSEMBLY Note: When reassembling housing components, apply silicone sealant as shown. Part No , LOCTITE SUPERFLEX 59630, THREE BOND 1281 or equivalent INSTALL NEW BEARING CUP INTO FRONT HOUSING 2. INSTALL IDLER GEAR AND GCD ASSEMBLY Install idler gear and GCD hemi assembly into front case.bearing cups Note: Input shaft may need to be tapped partially out to help locate idler 3. INSTALL REAR CASE ON TO FRONT CASE AND TAP HOME Torque up 8 bolts to: 37 N.m (27ft.lbf) 4. INSTALL INPUT SHAFT SNAP RING INTO REAR HOUSING. 4 2

5 5. INSTALL ORIGINAL IDLER SHAFT SHIMS Measure and confirm preload above case is within following specs. Thickness: Dim. A + 0.014-0.042 mm (0.0006-0.0017in.) 6.

4 5 5. INSTALL ORIGINAL IDLER SHAFT SHIMS Measure and confirm preload above case is within following specs. Thickness: Dim. A mm ( in.) 6. INSTALL NEW OUTPUT SHAFT REAR BEARING CUP Part No (Supplied in GCD Kit) and seat onto bearing SET REAR OUTPUT SHAFT PRELOAD Measure distance as shown from the case to the bearing cup and add the required preload as follows 6 12 Thickness: Dim B mm. ( in.) If not, select a shim from kit supplied to ensure correct preload INSTALL REAR EXTENSION HOUSING (b) Tap lightly with plastic hammer and seat home (c) Torque up 9 bolts to: 37 N.m (27ft.lbf) 9. ROTATE GCD SHAFT AND CONFIRM TURNING TORQUE with no shaft end play INSTALL ORIGINAL SPACER ONTO REAR OUTPUT SHAFT 11. INSTALL REAR CASE COVER Torque up 5 bolts to: 37 N.m (27ft.lbf) ONCE AGAIN CONFIRM GCD TURNING TORQUE PRELOAD INSTALL OUTPUT SHAFT COMPANION FLANGE Note: Make sure O-Ring is located in flange. 13. INSTALL, TORQUE AND STAKE LOCK NUT Torque nut to: 127N.m (94ft.ibf) FRONT EXTENSION HOUSING Note: Check condition of ball bearing and oil seal and replace if necessary INSTALL GCD FRONT OUTPUT SHAFT Using a press install the GCD front output shaft into the ball bearing INSTALL FRONT EXTENSION HOUSING AND SHAFT ONTO CASE Torque up 5 bolts to: 37 N.m (27ft.lbf) 16. INSTALL NEW GCD DRIVE FLANGE ONTO FRONT OUTPUT SHAFT 17. INSTALL SPECIAL WASHER 10 15, INSTALL, TORQUE AND STAKE GCD LOCKNUT Torque Locknut to 127N.m (94ft.lbf) 19. INSTALL SPEEDO DRIVE GEAR ASSY 19 3

5 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 anti-clockwise. 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 GD x GCD Hemi Assembly comprising: Hemi case with drive gear, CDA assembly and rear output shaft with 2 bearings installed (30210). GD x Front output shaft GD x Front drive flange GD x Lock nut GD x Washer GD x Bearing cups GD x Welch plug 27mm GD x Shim Kit GD x Installation manual GD x Caution sticker 4

(GD-12-1220) WASHER (GD-02-1210) LOCK NUT (GD-12-1200) REAR CASE DRIVE FLANGE (6208) CIRCUP BEARING FRONT EXTENTION HOUSING TOYOTA VDJ-70 SERIES COMPONENT ASSEMBLY NEW BEARING CUP (30210) SPACER

6 (GD ) WASHER (GD ) LOCK NUT (GD ) REAR CASE DRIVE FLANGE (6208) CIRCUP BEARING FRONT EXTENTION HOUSING TOYOTA VDJ-70 SERIES COMPONENT ASSEMBLY NEW BEARING CUP (30210) SPACER ADJUSTING SHIMS (GD ) (GD ) FRONT OUTPUT SHAFT SEAL O - RING LOCK NUT (GD ) 26 Hume Reserve Court, Nth Geelong Phone: (03) Fax: (03) COMPANION FLANGE ( ) (30210) NEW BEARING REAR EXTENSION HOUSING FRONT CASE LOW RANGE GCD HEMI ASSY GEARLESS CENTRE DIFFERENTIAL - Dedicated Low Range Conversion

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