Marlin Crawler gears to your Hilux - Simon
you are wanting to have lower gearing in your Hilux SFA then you
can consider the fitment of a Marlin Crawler kit, what you basically
require are the following items;
complete transfer cases. Which you will use only a section of the
A front cardan prop shaft.
A twin stick (gear lever).
Nibbler machine. (used to cut away the floor metal of your cab body)
Single front seats if your Hilux has the bench seat fitted.
New gearbox/transfer case rubber mounting block.
Various tools, basic socket and spanner set as well as a puller
New flange seals for the transfer case as well as two flange nuts
(new) cannot use the old nuts.
on the condition of the transfer cases, we recommend that you (or
you get The Marlin fitted by a business that reconditions gearboxes
and transfer cases) they can then also fit The Marlin Crawler adapter
plate and all new bearings at the same time or you can do the job
yourself, some advise, if you strip the transfer case's, take photo's
as you go along, we had our transfer case outer housing bead blasted,
please note, we did not fit The Marlin Crawler adapter plates ourselves,
we had them fitted by a business up in JHB called Mr Drive shaft
and Gearbox & Diff Centre Pierre tel 082 447 3237. You must
remember to fit a front transfer case flange at the rear of the
transfer case, the front and the rear flanges of the transfer case
are a different size.
also completely reconditioned the two gearboxes at the same time.
please note, only one of The Marlin Crawler kits was supplied by
Guy Heritage, the other was supplied by Riceburner who is another
member here :roll: also known as Darryl cell 083 307 6192, if you
are requiring Hilux items to modify your Hilux then give Darryl
a call, he can supply various lockers, Marlin Crawler kits and a
vast amount of other items as well.
am not going to go into the actual fitment of The Marlin Crawler
adapter kit to the transfer case, if you want to see how this is
done then you can visit Marlin's web site http://www.marlincrawler.com
who are in America, but we refitted the reconditioned gearbox as
well as the recon transfer case back into the vehicles, make sure
that you first fit a new rear main crank seal behind the fly wheel,
make sure that there are no high spots on the flywheel, if there
are then have it machined or fit a new flywheel, if you re-fit the
old flywheel, check that the ring gear teeth are still healthy (not
damaged), fit a new clutch kit which will also include a release
bearing, do not fit recon stuff, it might be cheaper but is rubbish,
go for a Sachs.
the gearbox and the transfer case is fitted, you now have to measure
up the correct length that the rear prop shaft will be, we decided
to remove and do away with the centre bearing on the std existing
rear prop shaft, with the added length of the additional transfer
case section and the adapter plate, we found that the angle of using
the two piece prop shaft would not be suitable, the angle is too
sharp, thus we obtained a front cardan prop shaft, modified it to
fit at the rear, this is why we fitted a front flange to the rear
of the transfer case, the front prop shaft will not fit to the std
rear flange of the transfer case.
the transfer case and gearbox were fitted, make sure that you do
not forget to fill both units up with the correct oil, we use a
GL 4 80 A gear oil, you can also lengthen the breathers if you want
We then measured up and cut a hole in the floor of the cab body
large enough for the twin shifter gear levers, the existing gear
lever that was used for the selection of the high/low and twd is
removed, what you will basically have is now four gear levers, the
small one will be re-fitted and will be used to select low or high
range only, forward will be low range and back high range, you still
will use the normal gear lever for the selection of 1st to 5th gears.
This is how you buy the kit and what it consists
Note the extended speedo cable.
You should have seen the face of The Landrover driver
this Marlin Crawler fitted, this is what it allows you to do, your
whole driving way changes
we have the rear prop shaft, we did away with the two piece prop
shaft and the centre bearing. See photo for details, I said earlier,
we have used a front prop shaft with the cardan joint at the rear.
you must also remember that this is a special rear modified prop
shaft, it has to also compensate for the rear revolver shackles
when we unlock them the rear axle drops down an extra 200mm.
Cardan Joint they cost about R3 500. (in 2007)
photo below shows the difference between the short normal std front
prop shafts and the longer modified front prop shaft that we have
used at the rear of my Hilux.
the extra low range, this Hilux performs differently, you have more
traction, you can handle the vehicle better, better control over
side angle terrain, helps to protect the vehicle against breaking
or abuse, but some warning, if we are out 4x4ing together, do not
drive behind me.
the twin shifter gives you the added gear selection and options,
until you have fitted this kit into your Hilux, you will not understand
the advantages of it until you have.
you are wanting to buy this kit and fit it into your Hilux, then
Burner here he can supply and maybe will fit it for you, if
you ask him nicely.