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Modifying the front Patrol Crossmember

This article is written to explain how to cut the front gearbox cross member.
The reason the cross member needs to be cut and modified is when a lift from 5 inch and above is performed on a patrol the tail shaft will make contact causing damage to both tail shaft and cross member.

This is a very simple procedure with only hand tools, grinder and welder needed.

Step 1
(image 1) shows the approx area needed to be cut out to allow enough room for clearance.
It is recommended to roughly mark the area to be cut out before removing the cross member.
You cannot cut too much of the right side away because the gearbox mount is located in this area.
047_400_01

(image 1)

Step 2.
Support the gearbox with a suitable gearbox jack and remove the front cross member.
(image 2) shows the actual area to cut out.
Engineer’s chalk is the best to use to mark the cut line.
050_400_01

(image 2)

Step 3.
Once the crossmember is removed and marked proceed to cut out the section needed to be removed.
Either a grinder with a cut off wheel, plasma cutter or oxy/acetylene can be used.
Clean up the area so a clean weld can be done.
052_400

(image 3)

Step 4.
The most common procedure is to place 2 plates at 90 degrees to each other and trim to the appropriate shape, if you have a bender you can bend up the 90 degree plate.
3-5mm steel is recommended.
As seen in the (image 4) the plates are tacked in place and now ready for welding.
056_400

(image 4)

Step 5.
Once welded coat the cross member with a good coat of etch paint and top coat to stop any corrosion.
060_400

(image 5)

Step 6.
Refit the cross member back in place and tighten the bolts to the factory torque settings, it is common for the cross member bolts to be rusty, if they are rusty it is recommended to replace them with new bolts.

Step 7.
This image shows full drop on a 5 inch lift kit, note there is sufficient clearance between the cross member and the tailshaft.
072_400_01

(image 6)

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