Toyo Koygo TK5 Xmsn

[geoflyer]

I have an '86 ranger 2wd i am converting to 4wd (Mitsu 2.3l diesel wont hardly pull a jet ski up a boat ramp, need low range) I can't seem to get my hands on a 4wd tk5. i have the 2wd tk5 (5spd) xmsn and my donor truck has the tk4 (4spd) 4wd xsmn. Looking at a xmsn parts breakdown and comparing part numbers their appears to be very little difference between the two xmsns. Has anyone out their successfully took the mainshaft and tail housing off of a 4wd and stuck them on a 2wd xmsn? the mitsu fm145 is longer so i'd probly have to have my driveshaft cut, and I absolutely have to use my bell housing as the gas burner bell housings won't fit my engine. truck is great on the highway and pulls a jet ski or small aluminum bass boat fine, but it doesn't have much grunt til the turbo kicks in.

 

[metalmacguyver]

I was wondering if anyone would ever build one of those old deisel rangers. Sorry i cant help you with your question as I am not familiar with those older trannys.

Do you have any pictures/plans?

 

[Jorley]

When my TK-5 went out it took me 2 months to find a replacement and it turned out to be bad. So I had 2 of them and mad 1 that worked. Here's something that might work.
I'll use this link for part numbers.

http://www.therangerstation.com/tech_library/pdf_documents/toyo83_87.pdf

Take the extension housing(part #7) from the 4-sp and put it on the 5-sp. I would try that before changing the main shaft because it can be a PITA. If you do have to change the mainshaft, Take pics at each stage and make sure to get all the thrust washers and spacers in the right places. Let me know how it goes, I have pics of when I did mine plus still have one apart.

 

[geoflyer]

Yeah i figured changing the mainshaft would be a barrel of fun. I think!!! a mitsu fm145 would bolt to my bellhousing but i'm not sure. I do know for a fact i'm stuck with my bellhousing.

 

[grnrngr]

I thought I could just swap the tail shaft housings, but no...it does involve taking the whole thing apart and swapping the output. I may end up doing that anyway, the used one I got from the wrecking yard is almost as bad as the one that broke.

 

[Jorley]

Yeah i figured changing the mainshaft would be a barrel of fun. I think!!! a mitsu fm145 would bolt to my bellhousing but i'm not sure. I do know for a fact i'm stuck with my bellhousing.

The FM-145 is 28.687" overall, the TK4 is 24" and the TK5 is 25.937". Are you sure the 2wd tranny is a TK5 and the 4x4 a TK4? The Tech Libray shows the TK5 as a 4x4 and the TK4 as 2wd.
http://www.therangerstation.com/tech_library/ManualTransmission.html

Any way here's apic of the TK5 diassembled.

 

[geoflyer]

yes the 4wd is a 4spd and my 2wd is a 5spd. I didn't catch the fact that the donor had a tk4 in it till i got it home Duh.

 

[Jorley]

Sorry for the dumb question. I have a bunch of pics of mine apart and as I said I have one still apart so if you need some help just let me know. The biggest problem I had was with the front bearing on the countershaft. You might consider just using the 4spd to save yourself some time and aggrevation. I put 31x10.50's on my truck and hardly ever use 5th anymore and pulling a trailer you also wouldn't use 5th. But as I said if you decide to do it and I can help just let me know.

 

[geoflyer]

I didn't think it was a dumb question. If i understand correctly you have successfully put the tail housing and output shaft from a 4sp onto a 5sp? This truck is my daily driver 2 and from work so i'd rather have the 5spd. My jeep grand Cherokee's gas mileage sucks! I may not even fully convert it to 4wd i just like to have low range.

 

[geoflyer]

Jorley the duh comment was not aimed at you, it was because i forgot some older rangers came with 4spd and i was 2 stupid 2 check the xmsn code or look at the shifter before i got it home. If i had i would have probably passed on it.

 

[Jorley]

Jorley the duh comment was not aimed at you, it was because i forgot some older rangers came with 4spd and i was 2 stupid 2 check the xmsn code or look at the shifter before i got it home. If i had i would have probably passed on it.

I know. I know the duh factor also. A fellow was parting out a '88 Bll so I got the manual tranny without knowing the '88 had A FM-146 and mine was a TK5. The FM-146 is 3" longer so I would have had to move the tranny crossmember and my drive shafts were the wrong lengths.

I didn't think it was a dumb question. If i understand correctly you have successfully put the tail housing and output shaft from a 4sp onto a 5sp? This truck is my daily driver 2 and from work so i'd rather have the 5spd. My jeep grand Cherokee's gas mileage sucks! I may not even fully convert it to 4wd i just like to have low range.

No, I had 2 TK5s that didn't work, so took parts to make 1 that did. Tranny shop wanted $600 to rebuild a TK5. So had no option but to do it myself. There are just some things I learned the hard way that I may be able to help you avoid. Took me 2 trys to get it right. Had to pull tranny once after I thought I had it fixed and start over. It's not alot of fun with no tranny jack or help.

 

[lodden758]

why don't you just use the four speed and diveshafts and stuff from the doner

 

[MAKG]

why don't you just use the four speed and diveshafts and stuff from the doner

I don't think there is any alternative that will actually work. There is no mainshaft in either of these transmissions that is the correct length to "convert" the TK5 to 4WD.

If you are going to buy parts, just buy a better transmission.

And don't forget to include driveshaft replacement in your budget. 2WD driveshafts are very different than 4WD driveshafts. It's not just length.

That TK5 pic is missing a few important parts. Like the front bearing retainer and shim, 5/R housing, and adapter.

 

[Jorley]

.

That TK5 pic is missing a few important parts. Like the front bearing retainer and shim, 5/R housing, and adapter.

It is also missing the 4th gear synchro blocking ring, rev. idler, countershaft rev. and overdrive gear and shifting shafts and forks, just to name a few. It is not, nor was it meant to be a technical or reference photo. It was purely meant basically to show someone who's never seen the inside of a tranny, what's in there.

 

[geoflyer]

Yeah I'm just gonna look for a donor. My rearend is 3.45 the donor has 3.08s. If convert it completely I'm gonna put a 4" lift and run 31's. which means putting 4.10's in to keep the rpms right. If i don't lift it and run 235/15s Im still gonna have to go to 3.73's. reason being i'm not working with a lot of hp(86) and I want to keep my fuel mileage. If i'm gonna drive an old truck its still gonna be a good looking truck. oh yeah a buddy of mine gave me a dead tk5 without a tail housing and i quickly realized there must be significant diffs in the tk4 and tk5. I already figured i'd have to have driveshafts made. $1500 in a drive to work beater still beats $50000 for a new 4wd diesel.