[hooki]

So after getting my F10a ready to put into the LJ all i had to do was bolt the LJ gearbox onto the engine. The only thing was i didnt realise the input shaft for the gearbox is 20mm longer than the input shaft in the maruti gearbox that came with the engine. So unaware of this i tightened the bellhousing bolts and just after they had some tension on them...BANG!... bellhousing split in half . Thats amature mechanics for you

So my question is, if i find another lj gearbox how do i go about shortening the input shaft 20mm?

Also, does anyone have a spare LJ80 gearbox for sale?

I have the maruti 4 speed that it came with but i dont really want to be fabbing new mounts and cutting a new hole in the tunnel for the shifter.

[hooki]

...

[Fatzook]

Ouch!!

I'd just be citting 20mm of the locating dowel.

Where does the spigot bearing run? Is it down near the spline? Or at the end of the dowel?

[hooki]

runs down near the splines i think. I geuss i'll have to find a replacement and then shorten the locating dowel. Real pain in the ass, that gear box only had about 35,000kms on it.

[Fatzook]

yeah that sucks

[Ben_Sierra]

Hooki, no promises mate, but I'll see if I can hook you up with an LJ80 box in Perth...

Dunno what I'll be able to find and in what condition but at the worst you may have to swap the internals from your current box...

[royce]

use an LJ flywheel not a maruti one is what the gurus would say I reckon

[303zuke]

It won't be the flywheel, it will be the depth of the spigot bearing hole in the end of the crank. As Fatzook, cut 20mm off the end of the shaft.....


BUT!! How are you going the fit the Maruti box into the LJ80? They are a different style of box and you won't be able use the Maruti box with the LJ80 Gear selector/adaptor thingy. The Maruti box is the same body as the Sierra 5 speed, so you can't use the upper and lower halves to repair the damaged LJ80 box.

[hooki]

That would be awesome Ben, finding one in Perth would make life alot easier.

Royce, I'm pretty sure that the flywheels are identicle, as 303zuke said it's the depth of the hole in the crank.

303zuke, I was thinking of using the muruti box but new mounts would need to fabbed and a new hole cut in the tunnel for the shifter.

[Ben_Sierra]

I phoned one mate and he doesn't have a 'box.

Another guy has a huge shed full of LJ parts but he's in the States for a couple of weeks, so I won't know until then if he has any...

I'll ask around at the club anyway...

[303zuke]

hooki wrote:

303zuke, I was thinking of using the muruti box and a new hole cut in the tunnel for the shifter.

Why not make a .wav file of fingernails scrtching down a chalkboard too and put it up on here for us to listen to?

Good unmolested LJ's are getting harder to find. Try not to bugger yours up. Have read of my 2nd post in This thread about how to convert the 5 speed into the LJ80. You've found one of the hard bits (Maruti front case), now you just need to find a Super Carry for the 5 speed internals and the shifter and selector rails. Look at the pic below. The upper pic is the Maruti case (you use the front upper and lower halves), and the bottom is the Super Carry case (you use all the internals and the rear case with the LJ80 shifter on top).

How much damage have you done to the LJ80 case? Is it both halves cracked, or just top or bottom. I might have something sitting around.

[hooki]

Ben_Sierra wrote:

I phoned one mate and he doesn't have a 'box.

Another guy has a huge shed full of LJ parts but he's in the States for a couple of weeks, so I won't know until then if he has any...

I'll ask around at the club anyway...

that would be great, cheers ben.

[hooki]

303zuke wrote:

hooki wrote:

303zuke, I was thinking of using the muruti box and a new hole cut in the tunnel for the shifter.

Why not make a .wav file of fingernails scrtching down a chalkboard too and put it up on here for us to listen to?

Good unmolested LJ's are getting harder to find. Try not to bugger yours up. Have read of my 2nd post in This thread about how to convert the 5 speed into the LJ80. You've found one of the hard bits (Maruti front case), now you just need to find a Super Carry for the 5 speed internals and the shifter and selector rails. Look at the pic below. The upper pic is the Maruti case (you use the front upper and lower halves), and the bottom is the Super Carry case (you use all the internals and the rear case with the LJ80 shifter on top).

How much damage have you done to the LJ80 case? Is it both halves cracked, or just top or bottom. I might have something sitting around.

It was only a passing thought about cutting a hole, but i dont want to hack anything up so it defently wont be happening. I like the sound of the 5 speed but i may wait and see if any lj boxes come up just because it will make life a bit easier. I'll hold onto the maruti box and hopefully build the 5 speed you have described a bit later down the track. At the moment i want to get the engine in asap so i can put the body on and start the body work.

I put a picture up above of the crack.

[2stroker]

Wow that is crazy, I havent come across this before, I fitted a maruti 1 litre to an LJ last week, no problem. I did however use the spiggot out of an LJ as the one in the 1 litre was knocked around.

I just went out and measured the depth of the hole in the end of the old 800 LJ crank and it is about 32mm deep. When I did the conversion the 800 spiggot tapped all the way in flush into the 1 litre so I didn't check the depth before assembling it. Can you tell us how deep the hole is in the 1 litre that you have please, there must be different depths, the engine I fitted was out of a 1988 Maruti.

This is one of those obscure things that needs to be committed to memory for future conversions I would hate to break a box like that.

If you must use a later top loader box just make a new tunnel cover from a piece of alloy sheet and cut the hole in that, don't hack up your original tunnel cover, keep it for later when you go back to stock.

As a side note the bushes in the gear linkage shaft were stuffed in the car I just did, it was the weekend and I couldn't get new ones so I turned some down from some neoprene suspension bushes I had on the shelf, the shift is unreal, better and more direct than any LJ I have ever had.

[mrw82]

When I installed a maruti 5 speed to my 1 litre (sierra) I noticed the different shaft lengths. the 4 speed box has a long spigot bearing shaft and the maruti had the shorter one. going by the wear marks on the 4 speed shaft the spigot bearing runs near the spline so the extra length is not needed.
I would assume that the maruti 1 litre engines have the shorter hole in the crank. a sierra 1 litre would have the deeper hole.

another thing hooki: PORL had/was going to get a 5 speed from a super carry but he didn't end up getting it as it wasn't going to work in his sierra. he may know if it's still available and you would be able to get the parts to do your 5 speed conversion.

or sell him the maruti 4 speed so he can convert it to 5 speed ( you can use 5th from any 1.3, it doesn't have to be from a super carry.

PORL is on your side of the world too.


I done a write up of my rebuild here: http://nbs4x4club.com/forum/index.php?topic=12545.0
but you need to be logged in to see the pics.

[2stroker]

I just found out that some of the 1 litre maruti engines have the spiggot in the flywheel not in the end of the crank and that the a flywheel is stepped outward.

On the LJ box the end of the input shaft protrudes by 10mm and it is 40mm from the edge of bellhousing back to spline, on the maruti series 2 box the input shaft is 10mm back from the edge of the bellhousing but the spline is still 40mm back.

I know it is not going to make all that much difference but did you use the sandwich plate between engine and box.

Also which flywheel did you use, LJ or Maruti

[Highway-Star]

2stroker wrote:

As a side note the bushes in the gear linkage shaft were stuffed in the car I just did, it was the weekend and I couldn't get new ones so I turned some down from some neoprene suspension bushes I had on the shelf, the shift is unreal, better and more direct than any LJ I have ever had.

Think I need to try this!

[tanshi]

me too!!!

[kenn]

I have a couple of LJ 80 gear boxes but i'm in Melbourne so if you want to orginize freight let me know.

[hooki]

i went and grabbed some rough measurements:

LJ crank hole depth 34mm
Maruti crank hole depth 20mm

LJ locating dowel length 50mm
Maruti locating dowel length 27-28mm

Flywheels are exactly the same apart from the size of the spigot bearing.
LJ spigot bearing size 17mm
Maruti spigot bearing size 25mm

The engine used is a 96' F10A. I did use the engine/bellhousing plate. I can see in the maruti crank hole some scratches caused by the lj locating dowel being to long.

[hooki]

thanks Kenn, i'm going to hunt for one in WA first but if i have no luck i'll get back to you. cheers.

[Ben_Sierra]

hooki, we are 95% sure the club has one, but its in the shed of the bloke who's in America at the minute, we need to check when he gets back.

The president wants $300 for it.

[tanshi]

might be cheaper to ship one from vic

[Ben_Sierra]

Maybe...

Its the only one we've got and they're hard to find, and with the number of LJ80s in the club we don't wanna let it go cheap and then have a member kill a box a few weeks down the track.

But if you want it let me know...

[hooki]

thanks for doing the ring around for me ben. I may be able to get something a little cheaper over east but if i have no luck i'll get back to you by the end of next week.

cheers.

[303zuke]

Have a yak to mrw82. His 1.0lt gearbox is the early type that will have the same front upper and lower case as the LJ80. With a bit of luck, he will have it in WA, not Qld.

[hooki]

just had a look and it says all items pick up from deception bay QLD, that sucks . 'Littlejeep' has offered me a trade, a LJ80 box for my maruti box. All we have to work out is postage. Anyone know of a good cheap courier company??

[Fatzook]

hooki wrote:

just had a look and it says all items pick up from deception bay QLD, that sucks . 'Littlejeep' has offered me a trade, a LJ80 box for my maruti box. All we have to work out is postage. Anyone know of a good cheap courier company??

www.e-go.com.au

[mrw82]

I will post it if you pay postage mate. just looking at the link fatzook posted up, I can drop the gearbox to their pinkenba depot, if you can pickup from forrestfield (if thats anywhere near you) you can do depot to depot and save 50%

im trying to workout what the rough postage cost would be for it.

[mrw82]

BAHAHAHAHAHA........ freight would cost $5.78 hahahahahaha.... thats rough calculations based on my estimates of size and weight of box.

would take 9 to 10 days though.


just checked, door to door would be about 12 bucks, depends on your postcode.