FZJ80 Toyota Land Cruiser Gearing - 4-Wheel & Off-Road

FZJ80 Toyota Land Cruiser Gearing - Crawl, Cruiser, Crawl! Fred Williams Brand Manager, Petersen’s 4Wheel & Off Road

The Toyota Land Cruiser has a long reputation as a great off-road vehicle, but over the years these trucks have gone from backcountry do-it-all to something of a glamorous luxo-ute. This doesn’t mean the newer Cruisers are any less capable, but there is a model that really was the pinnacle of performance in the U.S. and that was the FZJ80 Land Cruiser, ’93-’97. These were offered with front and rear selectable lockers in solid beam axles, coil-sprung suspension, and a torquey 4.5L straight-six engine.

Low gear increases from 2.4:1 to 3.1:1

Though they are capable out of the box, when we add upgrades like heavy bumpers and larger tires (and you know we will) they could always use more low-range gearing.

Marlin Crawler, a name synonymous with Toyota gearing, now offers lower low-range gearsets for the 80 and 100 series Cruisers (all ’91-’07 Land Cruisers). With a lower gearset the truck has more torque multiplication and a slower, more controlled crawling performance, and it can idle up large obstacles even when fitted with larger tires.

PhotosView Slideshow Unlike the doubler kits and many other low-gear installs common with transfer cases, the Marlin Crawler low gears can be swapped in without having to remove the transfer case from the Cruiser. The transfer case has a passenger-side rear output unlike many late-model transfer cases; this keeps both front and rear differentials in line as you’re driving down the trail. Rocky Gleason did the install in a day and started by removing the rear driveshaft and disassembling the rear two-thirds of the transfer case, while the front third and front driveshaft remain. A transmission jack helps support and lower the transfer case for access to the top of the case. The low-range motor actuator must be removed from the top of the case along with a small Torx bolt that retains the shifter detent ball and spring. This is the most difficult part of the job if you do it in the vehicle, as you are working blind. With the case disassembled the gearset is removed as a unit. The gearset will be cleaned and disassembled to fit the new lower gears. A press is needed to disassemble the low idler gear and the low gear from the factory differential case and idler gearshafts. A bearing splitter is helpful for this step to ease off the front tapered roller bearing. The new low gear increases the low range from 2.488:1 to 3.116:1. This is done by replacing the 40-tooth low gear and 19-tooth idler with a 58-tooth low gear and a 22-tooth idler gear. The new gears are AISI/SAE 8620 steel alloy and made in Japan. These Land Cruiser transfer cases have a center differential that is locked either in low range or via a button or viscous coupler in high range, depending on the year of the truck. There is another option whereby a center spool replaces the differential, and this allows the use of selectable front locking hubs. This upgrade improves steering and fuel economy slightly, and all the components for the upgrade are available through Marlin Crawler. A small bit of grinding is required to the aluminum case, shift fork, and a section of the steel oil slinger. Though this is possible to do with the front case half still in the vehicle, you’ll want to clean the case thoroughly with a shop vac, compressed air, and parts cleaner before final reassembly.