Quote:
Originally Posted by Dazza
it looks like, from reading the thread, that you bought a 3b and 5 speed(H55?), and used the existing transfer case from the fj60. is that right? (had to rotate motor mount setup to match 3b angle), new motor mounts...
other than that it seemed fairly straight forward... did I miss something?
did you have to do anything to the fuel tank?
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Its not done yet.... Straight forward or not really depends on your mechanical experience and how many tools / skills you have. You can outsource the minimal welding if needed, other than that specialty its not extrememly diffucult. Lots of details.
There are several threads on here regarding converting and FJ60 to 3B. Look around a bit becuase there isnt necessarily a right or wrong way to do it. If you can use what you have available and make or source the rest your conversion may be a bit different than others. Here is one in a 62
http://forum.ih8mud.com/60-series-wagons/139849-bj60-fj62-turbo%3D-bjt62.html
That said , here is what Im doing.
I removed a 3B and trans/transfer from a poorly converted FJ62. I neglected to keep a few parts off that rig due to condition and some ignorance on my part.
The easiest way to go would be to have a BJ60 donor vehicle and just transfer parts as needed.
At a minimum you will need the radiator and fan shroud from a BJ60 in addition to an engine/trans.
Then..
- Run a new line to move the clutch slave cylinder from the passenger side to the drivers side.
The rest is variable as there are several ways to do all of them.
- The motor mounts from the frame. You can cut the FJ mounts off and re-mount them, but the angle of the surface where the rubber motor mount fits is different. You will have to adjust for this angle when you weld them back on or fabricate new mounts - easier to use mounts from a BJ60 which is what I am doing.
- Trans cross member. Im re-using the one from the FJ. The angle I mentioned was due to the bell housing - not the transfer. Later model FJ60s have the trans/transfer rotated by the mount to the bellhousing. For this reason, the trans cross member is angled to accomodate the rotation. This one is a toss up to me. The BJ60 trans mount fits under the truck a little different and I probably would have modified it if I had it. All I did was add a shim and use the FJ rubber mount to the trans.
- Throttle linkage - again several options. Easiest to get the entire BJ60 throttle set up, but you could use parts from a 70, or an FJ62, or figure something out at the junkyard. You need something with a cable.
- glow plugs. You need to wire in a stock system or a simple system to power the glow plugs
- Other Wiring. Possibly easiest to use the wiring harness from a BJ60. Its a lot of work to mess with the entire harness though. There is not much to modify with the existing harness depending on whether or not you will use the EDIC system.
Im modifying the existing harness so I need to modify the connection to the alternator, and I will be making modifications to incorporate the edic motor and relay system. I will also be making mods to connect the starter , the starter solenoid, and the tach.
- vacuum - use the vacuum canister from a BJ or make your own. You need a reservoir to connect to the vacuum pump on the BJ alternator and you will need to route a line to the brake booster from the canister.
- power steering. The power steering pump is on the other side in a BJ. Use the BJ lines, or put something together with other parts. Im using the pressure lines from an FJ62 as its pump is also on the passenger side.
- Water lines. This is probably different depending on your year 60 and if you have a rear heater.
- Fuel system. Several things. The fuel filler on an FJ has a restrictor to prevent someone from putting Leaded fuel or diesel in. You need to modify the filler or get one from a BJ. The FJ fuel system also has return lines which you no longer need so these need to be addressed. You need to add a primary filter that also acts as a water seperator/sedimenter.
- exhaust - you will need a new exhaust system.
I am using the complete air cleaner assembly from a BJ60
I probably forgot something above....
I have made more progress on this and will post pics in the next day or two. Still not running, but it will be soon.