openinverter forum

Solition1DC wrote: ↑Tue Jan 17, 2023 5:43 pm GS450H GEARBOX > Rubber Mount > Bolted to driveshaft > ||| Driveshaft was cut + OE Gearbox Shaft was cut and Welded ||| > OE Gearbox driveshaft >> Insert into Transfercase

Any photos?

montyjohn wrote: ↑Sat Nov 26, 2022 6:59 pm I don't suppose you have any photos of the GS450H without the tail piece on?

I apologize for neglecting this thread! I am just picking up this project again. I just fetched a 2007 Tundra for sub $1k last week! I was about to use a 2005 Cayenne for the project but a 4x4 pickup truck is my preference... Next week, I should be able to test fit the JF1A transfer case shaft on my L110F transmission output shaft (When I realized the L110 was a no-go, I bought a L110F). I still need to go through the L110F tail housing to see if I can easily mill my own and transfer L110 tail housing Pawl assembly into it (that and the output shaft speed sensor are essentially all that are in the tail housing) to sell people, to expand the supply of 4x4 capable L110 gearboxes... it may me more difficult/expensive than what would be feasible, especially since the output shaft is not the same as the L110F either. I have the ability to cut splines/gears with 4 axis cnc milling but I don't have the ability to harden/temper my own parts.

Attached are my photos of the internals of the L110 / GS450h transmission tail housing (circa Jan 2021 - I didn't think to post them or check this thread at the time, sorry).

What I'd love to see is adapters for different propshaft flanges to the exg spline on the gs450h. Any chance you could measure the gs450h output shaft splines for me? Major diameter, nope diameter and number of teeth I guess. Thanks

Jacobsmess wrote: ↑Sat Jan 13, 2024 7:49 am What I'd love to see is adapters for different propshaft flanges to the exg spline on the gs450h. Any chance you could measure the gs450h output shaft splines for me? Major diameter, nope diameter and number of teeth I guess. Thanks

I already posted the number of teeth and major diameter 4 years ago: viewtopic.php?p=11390#p11390

celeron55 wrote: ↑Sat Jan 13, 2024 1:17 pm I already posted the number of teeth and major diameter 4 years ago: viewtopic.php?p=11390#p11390

Only got the number if teeth there from what I can see but useful nonetheless... Although unfortunately the rest of your post suggests it's unlikely I'll find a replacement flange with my required bolt spacing.

Jacobsmess wrote: ↑Sat Jan 13, 2024 4:45 pm Only got the number if teeth there from what I can see but useful nonetheless... Although unfortunately the rest of your post suggests it's unlikely I'll find a replacement flange with my required bolt spacing.

The diameter is in the photo with the calipers. The sealing diameter also.

TinkerTan wrote: ↑Sat Jan 13, 2024 5:46 am I apologize for neglecting this thread! I am just picking up this project again. I just fetched a 2007 Tundra for sub $1k last week! I was about to use a 2005 Cayenne for the project but a 4x4 pickup truck is my preference... Next week, I should be able to test fit the LF1A transfer case shaft on my L110F transmission output shaft (When I realized the L110 was a no-go, I bought a L110F). I still need to go through the L110F tail housing to see if I can easily mill my own and transfer L110 tail housing Pawl assembly into it (that and the output shaft speed sensor are essentially all that are in the tail housing) to sell people, to expand the supply of 4x4 capable L110 gearboxes... it may me more difficult/expensive than what would be feasible, especially since the output shaft is not the same as the L110F either. I have the ability to cut splines/gears with 4 axis cnc milling but I don't have the ability to harden/temper my own parts.

Attached are my photos of the internals of the L110 / GS450h transmission tail housing (circa Jan 2021 - I didn't think to post them or check this thread at the time, sorry).

Glad to see you back at this project! I am also using the LS600H transmission in my build and would be interested to see if there is another transfer case compatible with the stock transmission that is not full-time AWD to help improve range when AWD is not needed.

robertwa wrote: ↑Sun Jan 21, 2024 5:09 pm Glad to see you back at this project! I am also using the LS600H transmission in my build and would be interested to see if there is another transfer case compatible with the stock transmission that is not full-time AWD to help improve range when AWD is not needed.

Indeed, the L110F output shaft does mate to the JF1A transfer case on the 2nd Gen Tundra with 4.7L 2UZ and 4.6 1UR. I have not been able to test a JF3A and won't likely have a chance to in the near future.

I just pulled this out of my truck a half hour ago to verify fitment of the shafts. Indeed, I do need to get a larger ID shaft seal for the L110F output. The next items of business are to grab 3d scans of both faces, model the adapter and mill one out. It'll be quite a large adapter plate, but it should still easily fit on my 4th axis (to reduce setups of course).

Update on impending progress 2/1/2024
I have found a shaft seal which should suffice for the L110F output shaft (seal around the OD of the female splined JF1A input shaft), though it is 1mm short and will sit recessed as much in the seal bore. The ID and OD match. The 710407 (Timken and National Oil Seals) is the only seal I could find which would work and I had to buy a couple on ebay, as they are backordered everywhere else I looked. I will update the forum on the shaft seal fitment when they arrive.

I am still actively working to design and mill out an adapter plate/block (am appropriate billet of 6061 or 7075 will likely be a few hundred dollars, as it will be about 2.5x12x12 to fit both flanges obout the centerline). The 3D scanning method of retrieving accurate critical dimensions has proven to be much more difficult than one would expect...

This may be my solution for electrifying a Toyota Hilux Surf gen 3.

My transfer case adapter solution is ongoing, but I have a scrappy cut and welded adapter basically completed. I cut the flanges off my A750F extension housing and off the LF1A tcase (a perfectly good tcase from a $110k LS600...). I welded the flanges to make an adapter. Although I was careful about thermal expansion and warpage while Aluminum MIG welding those, I ended up with an adapter too thin and with .030" parallelism across the width of the JF2A flange width: ~10inches. I will need to mill the faces of the adapter parallel then use a shim for now... but now I can move forward with mounting the transmission with transfer case in my truck and start building my inverter and trans harnesses, front transmission mounts, etc...
Although I set aside my 3D modeling and machining of the adapter to more quickly cut and weld an adapter together, I do plan to return to that soon, in order to end up with a stronger tcase adapter and to be able to provide you all with an adapter solution for 4WD with the L110F (with JF2A or JF3A).