gearbox swapping.

[Stu.wrf450]

Has anyone put a prado 6sp auto into a hilux 4 speed auto?

[mattwhite]

They're only 5 mate. Toyota started doing it last year.

[rory18]

Unless he meant the 6 sped manual? Someone a while back claimed they did the swap from 5 speed man to 6 speed man.

[packeteer]

Unless he meant the 6 sped manual? Someone a while back claimed they did the swap from 5 speed man to 6 speed man.

I'd like to do that, but haven't found any info

[rory18]

Somewhere on this forum there was tiniest bit of info. Not sure if the guy was legitimate about his claims but seems feasible

[Stu.wrf450]

Sorry the 5 speed auto. I thought they where puttinf a 6 speed auto in the prados.

[Philby]

Unless he meant the 6 sped manual? Someone a while back claimed they did the swap from 5 speed man to 6 speed man.

I'd like to do that, but haven't found any info

Hi all, Yep I have fitted the Prado 6 speed gearbox in place of the Hilux 5 speed gearbox. The biggest stumbling block is fitting the Hilux transfer case to the 6 speed. The bolt pattern is the same but the transfer case input shaft has to be changed to suit the output shaft of the 6 speed. I had to source the parts from a Tacoma in the states.
If anyone is keen I'm happy to assist.
In regards to replacing the 4 speed auto with the 5 speed auto, if it fits, you will have to change the ecu which not only controls the engine but also the auto.
Cheers.

[packeteer]

any chance of write up?

[rory18]

Philby, could you link in the part you sourced from Tacoma?

[StevenS]

Unless he meant the 6 sped manual? Someone a while back claimed they did the swap from 5 speed man to 6 speed man.

I'd like to do that, but haven't found any info

Hi all, Yep I have fitted the Prado 6 speed gearbox in place of the Hilux 5 speed gearbox. The biggest stumbling block is fitting the Hilux transfer case to the 6 speed. The bolt pattern is the same but the transfer case input shaft has to be changed to suit the output shaft of the 6 speed. I had to source the parts from a Tacoma in the states.
If anyone is keen I'm happy to assist.
In regards to replacing the 4 speed auto with the 5 speed auto, if it fits, you will have to change the ecu which not only controls the engine but also the auto.
Cheers.

How do the ratios suit the Lux in driving around town?

the Hilux in 4th gear at 60km/h isn't overly happy but 3rd gear feels too high half the time. The Prado 4th gear is about halfway between our 3rd and 4th so would seem to be a good medium.

The prado 1st is a bit lower than the Hilux so could affect towability, though not by much

[rory18]

5th gear in the prado is 1:1 same as 4th in a hilux

Prado
1st = 4.171
2nd = 2.190
3rd = 1.488
4th = 1.193
5th = 1.000
6th = 0.799
Reverse = 3.607

Hilux
1st = 4.313
2nd =2.330
3rd = 1.436
4th = 1.000
5th = 0.838
Reverse = 4.220

[StevenS]

5th gear in the prado is 1:1 same as 4th in a hilux

That too, so you have more options at 60km/h

[Philby]

any chance of write up?

Ok.. Not much of a story writer but I'll give it a go...Looking for pics now but all I found was a virus

[Philby]

Philby, could you link in the part you sourced from Tacoma?

Hi all, here is a list of parts I used to convert my top shift transfer case. Sorry... no photo's as yet....still looking....

P/N...... 36102-35080......... Front Cover Ass.
P/N...... 36201-35130......... Input Shaft
P/N...... 96721-35063......... O ring
P/N...... 04362-60780......... Gasket Kit
P/N...... 08826-00090......... Red Silicone Sealant

Any further questions...... happy to assist

Cheers.....

[pisso01]

How do you find the gearing and what size tyres do you run? This sounds interesting.

Cheers,

Chris.

[Philby]

Hi All, Here goes my attempt at the good (Prado Gearbox) the bad (the transfer case) and the ugly (my transcript).

The 6 sp gearbox is basically a straight bolt up with both the cross member and hole for the gear lever all in allignment, except for one bolt on the bell housing which does not line up, left it out.
Things to be aware of are the gearbox imput shaft, which can vary from 29.0-29.8mm,this determines which clutch to run (Prado or Hilux). You will also notice on the pic the absence of the spigett. After taking measurements, I realised you can actually leave the spigett bearing in place regardless of the spigett being present or not. I chose to leave the bearing in tact.

Hilux Gearbox (model #R150F)
http://s896.photobucket.com/user/pc919/ ... 8180507529

Prado Gearbox (model #RA61F)
http://s896.photobucket.com/user/pc919/ ... 1191601793

I found the Hilux gear lever ended up being too high, so I shortened it by about 50mm, my preference, to each their own. Could have bought a Prado stick at $450 from Toyota but decided to use what I had. With a Prado stick the following would also not be an issue. The bush at the bottom of the gear lever which sits in the selector rail is too small, so I machined a sleeved to fill the void and address the issue. See following pic, left is the Hilux, right is the Prado.

http://s896.photobucket.com/user/pc919/ ... 2843049186

The transfer case..... the hilux tc bolt pattern suits the bolt pattern of the 6sp box but the output shaft of the gearbox and the imput shaft of the tc are totally different.

Output shaft of 6sp gearbox
http://s896.photobucket.com/user/pc919/ ... 3618370636

Hilux (L) (model #VF2A)and Prado (R) (model# VF4B) transfer case
http://s896.photobucket.com/user/pc919/ ... 3618370636

My first attempt to was to try and utilise the imput shaft from the Prado tc to see if that would fit into the Hilux tc but as you will see by the following pic.......this is not the case.

Hilux (L) and Prado (R) transfer case imput shafts
http://s896.photobucket.com/user/pc919/ ... 3618370636

You can use the Prado tc (constant 4WD Hilux) but the issue there is the difference between flanges for the prop shafts. The rear shaft needs to be shortened by 30mm and the front shaft lengthened by 30mm.

Realising that the US Tacoma utilizes the same gearbox and transfer case, I scoured the parts manuals on the world wide web to find and identify the necessary parts to convert a 5sp case into a 6sp case and so I procured these parts from the US of A..

The next pic shows you the differences between the 5sp and 6sp transfer case imput shafts.
Hilux (L) and Prado (R)
http://s896.photobucket.com/user/pc919/ ... 3618370636

Here is the 6sp tc already for attachment to the 6sp gearbox
http://s896.photobucket.com/user/pc919/ ... 3618370636

And here it be altogether....... of course the shiny one is the 6spd.
http://s896.photobucket.com/user/pc919/ ... 3618370636

The final drive ratio has been maintained as there is a difference. 5sp 3.583 and the 6sp 3.727
To continue answering questions posted, my tyre sizes are 265/65/R17.

The only major difference is my wife cannot find reverse, she finds first instead . Speaking of reverse the ratios are Hilux 4.220 vs Prado 3.607. Due to this, you will find reverse is slightly quicker. I find 1st gear great for hauling the boat out and getting 2ton of hilux out first from the traffic lights. (wife!) 3rd and 4th ratios are good for driving around town especially when you have about 6 speed zones within 10 km from home.

So guys there you have it, any questions am happy to assist, however I will be out of range for the next week so. Will get back to you as soon as I can Cheers Philby

[Philby]

Hi All, Here goes my attempt at the good (Prado Gearbox) the bad (the transfer case) and the ugly (my transcript).

The 6 sp gearbox is basically a straight bolt up with both the cross member and hole for the gear lever all in allignment, except for one bolt on the bell housing which does not line up, left it out.
Things to be aware of are the gearbox imput shaft, which can vary from 29.0-29.8mm,this determines which clutch to run (Prado or Hilux). You will also notice on the pic the absence of the spigett. After taking measurements, I realised you can actually leave the spigett bearing in place regardless of the spigett being present or not. I chose to leave the bearing in tact.

Hilux Gearbox (model #R150F)
http://s896.photobucket.com/user/pc919/ ... 8180507529

Prado Gearbox (model #RA61F)
http://s896.photobucket.com/user/pc919/ ... 1191601793

I found the Hilux gear lever ended up being too high, so I shortened it by about 50mm, my preference, to each their own. Could have bought a Prado stick at $450 from Toyota but decided to use what I had. With a Prado stick the following would also not be an issue. The bush at the bottom of the gear lever which sits in the selector rail is too small, so I machined a sleeved to fill the void and address the issue. See following pic, left is the Hilux, right is the Prado.

http://s896.photobucket.com/user/pc919/ ... 2843049186

The transfer case..... the hilux tc bolt pattern suits the bolt pattern of the 6sp box but the output shaft of the gearbox and the imput shaft of the tc are totally different.

Output shaft of 6sp gearbox
http://s896.photobucket.com/user/pc919/ ... 3618370636

Hilux (L) (model #VF2A)and Prado (R) (model# VF4B) transfer case
http://s896.photobucket.com/user/pc919/ ... 3618370636

My first attempt to was to try and utilise the imput shaft from the Prado tc to see if that would fit into the Hilux tc but as you will see by the following pic.......this is not the case.

Hilux (L) and Prado (R) transfer case imput shafts
http://s896.photobucket.com/user/pc919/ ... 3618370636

You can use the Prado tc (constant 4WD Hilux) but the issue there is the difference between flanges for the prop shafts. The rear shaft needs to be shortened by 30mm and the front shaft lengthened by 30mm.

Realising that the US Tacoma utilizes the same gearbox and transfer case, I scoured the parts manuals on the world wide web to find and identify the necessary parts to convert a 5sp case into a 6sp case and so I procured these parts from the US of A..

The next pic shows you the differences between the 5sp and 6sp transfer case imput shafts.
Hilux (L) and Prado (R)
http://s896.photobucket.com/user/pc919/ ... 3618370636

Here is the 6sp tc already for attachment to the 6sp gearbox
http://s896.photobucket.com/user/pc919/ ... 3618370636

And here it be altogether....... of course the shiny one is the 6spd.
http://s896.photobucket.com/user/pc919/ ... 3618370636

The final drive ratio has been maintained as there is a difference. 5sp 3.583 and the 6sp 3.727
To continue answering questions posted, my tyre sizes are 265/65/R17.

The only major difference is my wife cannot find reverse, she finds first instead . Speaking of reverse the ratios are Hilux 4.220 vs Prado 3.607. Due to this, you will find reverse is slightly quicker. I find 1st gear great for hauling the boat out and getting 2ton of hilux out first from the traffic lights. (wife!) 3rd and 4th ratios are good for driving around town especially when you have about 6 speed zones within 10 km from home.

So guys there you have it, any questions am happy to assist, however I will be out of range for the next week so. Will get back to you as soon as I can Cheers Philby

Knew I'd forget something, the clutch slave cylinder.... to maintain clutch travel, I had to sleeve the Prado Slave Cylinder down from 20.5mm to 19mm, see below as above, Hilux L and Prado R
http://s896.photobucket.com/user/pc919/ ... 1.jpg.html?
sort=3&o=6#/user/pc919/media/IMG_0211.jpg.html?sort=3&o=6&_suid=1422883064861016086353520170116

I have used the Hilux Slave Cylinder internals into the sleeved Prado Cylinder Cheers

[packeteer]

cheers for that mate. awesome work!

[angusjones8]

Toyota please take note!!!


Cant imagine a prado 6 speed would be too cheap but sounds like a easy enough swap.

[StevenS]

Ive seen them for about 2k without the transfer at the wreckers
Be a very distinct change to the ute but would you also need a new clutch etc?