FZJ80 + Taco 6 speed + Orion

bjowett · 07-15-05, 03:43 PM

Well, things are getting out of hand with the latest project, so I figure it is about time to move it on over here to Hardcore.

For those that don't read the 80 section, have a look here for the beginings of this project.

http://forum.ih8mud.com/80-series-tech/47895-6-speed-bling.html

I'm working on installing a Aisin RA60 6 speed Tacoma manual transmission behing my soon to be built 4.6L 1FZ. After weeks of deliberation on what to do in order to get a proper low range, it has been decided that the AA Orion 4.00 - 1 transfer case kit is the way to go.

In order to get the Orion to fit the 19 spline RA60 output shaft, the gear will have the center milled out, splined, and then be press fitted to a large splined adapter. This adapter is actually a piece from the stock HF2AV transfer case... it will be machined in various ways to accept bearings, seals, and the gear.

Pictures soon.

Mace · 07-15-05, 04:13 PM

Why not just do an atlas?

woody · 07-15-05, 04:14 PM

this sounds very kewl...and lets ya keep the stock offset 80-axles intact...

hurry up with the bloody pics!!

Tigerstripe40 · 07-15-05, 05:16 PM

I think this sums it up...

bjowett · 07-15-05, 05:33 PM

Quote:

Originally Posted by Mace

Why not just do an atlas?

Woody answered the first part, keeping the stock offset axles. The gas tank would need to modding, too.

bjowett · 07-15-05, 10:14 PM

Pics of "stuff"... Orion is on the way.

Transmission sans tail housing, note the nice long 19 spline output.

This is the input/main shaft from the HF2AV partially slipped onto the output. The input gear is press fit on here, the shaft is roughly 1 7/8" diameter and 44 spline. If anything has a chance of holding a custom splined gear, this shaft does.

Here are the input gears, counter clockwise from top left 16 spline 77' case, 19 spline 87' split case, 44 spline 93' HF2AV.

reffug · 07-16-05, 06:42 AM

So does this mean there will be no more updates in 80's tech?

Not that big of a deal since I frequently come in here to look around and drool but alot of the fella's will be missing out.

bjowett · 07-16-05, 07:31 AM

I can update the 80's section... Just figured with all the mods required to fit this combo, it is way beyond bolt in, thus fewer folks will be interested there.

concretejungle · 07-16-05, 09:54 AM

Just link it fugger!

Eskimo · 07-17-05, 07:55 AM

That is very cool indeed, but isn't the 80 axle only like 4" offset? I would think that hardly matters if you were to run a centered rear output..

But anyway, certainly out of the box..

bjowett · 07-17-05, 08:45 AM

The gas tank is in the way of a centered shaft, I also believe some of the body or frame may be in the way also.

wngrog · 07-17-05, 10:52 AM

Quote:

Originally Posted by bjowett

The gas tank is in the way of a centered shaft, I also believe some of the body or frame may be in the way also.

Manaul trannys SUCK!

Cool idea though

bjowett · 07-17-05, 03:42 PM

Automatic transmissions suck, they are for lazy old people who want to look experienced when driving offroad.

euclid · 07-17-05, 05:20 PM

Quote:

Originally Posted by bjowett

Automatic transmissions suck, they are for lazy old people who want to look experienced when driving offroad.

Or for anyone who want to drive over obstacles very smoothly without spining a tire or burning up a clutch.

foxfab · 07-17-05, 05:52 PM

Brian get my vote for the most "outta the box" thinker. First the turbo 4Runner on FZJ80 axles and suspension, now this? Hey, once this is done and you sell it for 1/2 of what its worth, lemme know.

bjowett · 07-17-05, 07:32 PM

Quote:

Originally Posted by euclid

Or for anyone who want to drive over obstacles very smoothly without spining a tire or burning up a clutch.

No burny burny with 4.17 x 4.00 x 4.88... only old lazy people with automatics worry about spinning tires anyway.

In all seriousness, automatics do an excellent job in some situations.

I made a smidge on the last rig, plus I got to wheel it for 2 years.... No 80 for you!

Rascal · 07-17-05, 07:42 PM

Brian,

Keep the posts coming. Very interesting idea. Look forward to watching it come together.

euclid · 07-17-05, 11:06 PM

True. True.

Quote:

Originally Posted by bjowett

No burny burny with 4.17 x 4.00 x 4.88... only old lazy people with automatics worry about spinning tires anyway.

In all seriousness, automatics do an excellent job in some situations.

dieseldog · 07-18-05, 12:50 AM

Very sweet. I'll be trying to figure out how to mount a LC split transfercase behind a HiLux/Surf (4Runner) auto tranny. I am thinking about a Marlin Crawler toybox with the front built to adapt to the HiLux slushbox and the rear made to adapt to the split TC. With the toybox in place, my crawl options would be amazing.

(Side note: my project involves pulling the H diesel drivetrain out of my HJ-45 and installing a 1KZ-TE turbodiesel/slushbox pulled from a JDM half-cut. I want to keep my LC offset full-float rear axle and end up with a KZJ-45.)

Bryan062087 · 07-19-05, 09:14 PM

i know some1 who had a 6 speed put in his 60

keep up the good work

bjowett · 07-29-05, 11:36 AM

Number 241 has arrived... the fun begins next week!

bjowett · 08-03-05, 01:22 PM

The 1FZ has officially joined the 6 speed RA60 transmission. The mounting flange from the old A442 bellhousing was cut and removed, then TIG welded directly to the RA60 bellhousing. A few redundant steel braces will help support the weld... cast aluminum is cast aluminum, after the TIG is done, it can only be so strong.

Centering the transmission to the engine was a slight challenge due to the fact that the RA60 uses no pilot bearing. A 3.5" long sleeve was machined and used in much the same way that a clutch alignment tool is used. The sleeve slides over the transmission's input shaft, and then slides into the pilot bearing hole in the crankshaft as the transmission is set into place against the back of the engine.

Now on to machining the flywheel and adapting the Orion....

lowtideride · 08-04-05, 05:53 PM

its about damn time yous 80s tech people stop talking about leather seats....awesome job bro

concretejungle · 08-04-05, 07:33 PM

Quote:

Originally Posted by lowtideride

its about damn time yous 80s tech people stop talking about leather seats....awesome job bro

bkg · 08-07-05, 09:27 PM

Quote:

Originally Posted by bjowett

Centering the transmission to the engine was a slight challenge due to the fact that the RA60 uses no pilot bearing. A 3.5" long sleeve was machined and used in much the same way that a clutch alignment tool is used. The sleeve slides over the transmission's input shaft, and then slides into the pilot bearing hole in the crankshaft as the transmission is set into place against the back of the engine.

No pilot bearing? From your post, I can't tell what supports the input shaft???

bjowett · 08-07-05, 10:44 PM

Yup... no pilot bearing is used. Just like the old front drive cable clutch VW's. The main shaft is very long and gear reduction is done on the output shaft side. All support is internal to the transmission. Nothing explains(??) it better than the picture of the shafts....

MoJ · 08-23-05, 02:00 PM

Brian -

How's the project going?

bjowett · 08-23-05, 09:12 PM

The shortblock is together and the flywheel is almost complete....

Flywheel chunk....

roughed in...

Should have the final pic of it this week.

07-15-05, 03:43 PM	#1
bjowett IH8MUD Lifer Join Date: Oct 2002 Posts: 1,782	FZJ80 + Taco 6 speed + Orion Well, things are getting out of hand with the latest project, so I figure it is about time to move it on over here to Hardcore. For those that don't read the 80 section, have a look here for the beginings of this project. http://forum.ih8mud.com/80-series-tech/47895-6-speed-bling.html I'm working on installing a Aisin RA60 6 speed Tacoma manual transmission behing my soon to be built 4.6L 1FZ. After weeks of deliberation on what to do in order to get a proper low range, it has been decided that the AA Orion 4.00 - 1 transfer case kit is the way to go. In order to get the Orion to fit the 19 spline RA60 output shaft, the gear will have the center milled out, splined, and then be press fitted to a large splined adapter. This adapter is actually a piece from the stock HF2AV transfer case... it will be machined in various ways to accept bearings, seals, and the gear. Pictures soon. __________________ Brian Western Massachusetts 08 Tundra Double Cab 5.7 TRD 93 FZJ80, locked, 4.6L, 6 speed, Orion <- now driving! 04 VW Touareg V8 w/ locker (hers) 80 FJ40 , 83k, PS and AC 05 Yamaha RS Rage Snowmobile 06 Suzuki King Quad 93 VW Corrado Syncro AWD 3.0L 51 Jowett Jupiter Roadster

07-15-05, 04:13 PM	#2
Mace what he said Join Date: Feb 2002 Location: Las Vegas Posts: 11,191	Why not just do an atlas? __________________ I am kinda gay....... My Myspace http://profile.myspace.com/index.cfm...endid=75712409 "Mary Poppins: In every job that must be done, there is an element of fun. You find the fun and - SNAP - the job's a game."

07-15-05, 04:14 PM	#3
woody Admin Join Date: Jan 2002 Location: Appleton, WI TLCA# 1548 Posts: 7,676 Blog Entries: 1	this sounds very kewl...and lets ya keep the stock offset 80-axles intact... hurry up with the bloody pics!! __________________ Brian 'woody' Swearingen 1974 FJ40 'The Raisin' - Pitbull Rockers, 30-spline Longfields, SOA - 1/4 ellip 1996 FZJ80 'Gretchen' - MetalTech, ARB, OME, IPOR, 4x4Labs 2003 2500HD Duramax - Edge/Juice/Attitude, 285 Nitto Terra Grapplers, 4" exhaust 'America will never be destroyed from the outside. If we falter and lose our freedoms, it will be because we destroyed ourselves.' Abraham Lincoln

07-15-05, 05:16 PM	#4
Tigerstripe40 IH8MUD Addict Join Date: May 2004 Posts: 916	I think this sums it up... __________________ James Henry Wasatch Cruisers TLCA 11233 76 FJ40 'SeldomSeen' 91 VZN130 'CanOWorms'

07-15-05, 10:14 PM	#6
bjowett IH8MUD Lifer Join Date: Oct 2002 Posts: 1,782	Pics of "stuff"... Orion is on the way. Transmission sans tail housing, note the nice long 19 spline output. This is the input/main shaft from the HF2AV partially slipped onto the output. The input gear is press fit on here, the shaft is roughly 1 7/8" diameter and 44 spline. If anything has a chance of holding a custom splined gear, this shaft does. Here are the input gears, counter clockwise from top left 16 spline 77' case, 19 spline 87' split case, 44 spline 93' HF2AV. __________________ Brian Western Massachusetts 08 Tundra Double Cab 5.7 TRD 93 FZJ80, locked, 4.6L, 6 speed, Orion <- now driving! 04 VW Touareg V8 w/ locker (hers) 80 FJ40 , 83k, PS and AC 05 Yamaha RS Rage Snowmobile 06 Suzuki King Quad 93 VW Corrado Syncro AWD 3.0L 51 Jowett Jupiter Roadster Last edited by bjowett; 08-15-06 at 04:29 PM.

07-16-05, 06:42 AM	#7
reffug grown up MOD Join Date: May 2004 Location: 'in dat der briar patch' TLCA# 14549 Posts: 3,777	So does this mean there will be no more updates in 80's tech? Not that big of a deal since I frequently come in here to look around and drool but alot of the fella's will be missing out. __________________ "If it wasn't a Landcruiser and hadn't been built the way it was you do realize you would be DEAD." VA State Police Officer

07-16-05, 07:31 AM	#8
bjowett IH8MUD Lifer Join Date: Oct 2002 Posts: 1,782	I can update the 80's section... Just figured with all the mods required to fit this combo, it is way beyond bolt in, thus fewer folks will be interested there. __________________ Brian Western Massachusetts 08 Tundra Double Cab 5.7 TRD 93 FZJ80, locked, 4.6L, 6 speed, Orion <- now driving! 04 VW Touareg V8 w/ locker (hers) 80 FJ40 , 83k, PS and AC 05 Yamaha RS Rage Snowmobile 06 Suzuki King Quad 93 VW Corrado Syncro AWD 3.0L 51 Jowett Jupiter Roadster

07-16-05, 09:54 AM	#9
concretejungle IH8MUD Lifer Join Date: Oct 2003 Location: North Cadillac TLCA# 14646 Posts: 6,176	Just link it fugger! __________________ 95' FZJ80 OME med./J lift, ARB rack, ARB Bull Bar w/tmax 12,500, 315 Nitto, stainless brake lines, Center Diff Lock, Sliders, IPOR Skid, IPOR rear bumper, upgraded slee sticker, custom dents, more to come. . . Remember it's a gateway drug, so it will actually lead to "crystal meh".

07-17-05, 07:55 AM	#10
Eskimo IH8MUD Lifer Join Date: Sep 2002 Location: Danville, PA Posts: 1,166	That is very cool indeed, but isn't the 80 axle only like 4" offset? I would think that hardly matters if you were to run a centered rear output.. But anyway, certainly out of the box.. __________________ Rich in NC FJ - '73 FJ-40 Cruggy - LSx/4-wheel steer Rockwells/4-link/coilovers/42's Build thread --> http://forum.ih8mud.com/hardcore-corner/124040-keeping-low-rockwells-k-under-knife-again.html '01 Chevy 2500HD 8.1 Allison Lux-o-tow

07-17-05, 08:45 AM	#11
bjowett IH8MUD Lifer Join Date: Oct 2002 Posts: 1,782	The gas tank is in the way of a centered shaft, I also believe some of the body or frame may be in the way also. __________________ Brian Western Massachusetts 08 Tundra Double Cab 5.7 TRD 93 FZJ80, locked, 4.6L, 6 speed, Orion <- now driving! 04 VW Touareg V8 w/ locker (hers) 80 FJ40 , 83k, PS and AC 05 Yamaha RS Rage Snowmobile 06 Suzuki King Quad 93 VW Corrado Syncro AWD 3.0L 51 Jowett Jupiter Roadster

07-17-05, 03:42 PM	#13
bjowett IH8MUD Lifer Join Date: Oct 2002 Posts: 1,782	Automatic transmissions suck, they are for lazy old people who want to look experienced when driving offroad. __________________ Brian Western Massachusetts 08 Tundra Double Cab 5.7 TRD 93 FZJ80, locked, 4.6L, 6 speed, Orion <- now driving! 04 VW Touareg V8 w/ locker (hers) 80 FJ40 , 83k, PS and AC 05 Yamaha RS Rage Snowmobile 06 Suzuki King Quad 93 VW Corrado Syncro AWD 3.0L 51 Jowett Jupiter Roadster

07-17-05, 05:52 PM	#15
foxfab IH8MUD Lifer Join Date: Aug 2004 Location: NK, RI TLCA# 9838 Posts: 2,130	Brian get my vote for the most "outta the box" thinker. First the turbo 4Runner on FZJ80 axles and suspension, now this? Hey, once this is done and you sell it for 1/2 of what its worth, lemme know. __________________ YANKEETOYS.ORG Member of the elite FJ25 club Low range? We Don't Need No Stinkin' Low Range Why would you want to put a round tire in a square wheel well?

07-17-05, 07:42 PM	#17
Rascal IH8MUD Addict Join Date: Jun 2003 Location: Argyle, TX TLCA# 12347 Posts: 535	Brian, Keep the posts coming. Very interesting idea. Look forward to watching it come together. __________________ Bruce Mitchell 07 TLC - It's nice to be back...

07-19-05, 09:14 PM	#20
Bryan062087 IH8MUD Regular Join Date: Mar 2005 Location: Memphis, TN Posts: 490	i know some1 who had a 6 speed put in his 60 keep up the good work __________________ 89 FJ62

07-29-05, 11:36 AM	#21
bjowett IH8MUD Lifer Join Date: Oct 2002 Posts: 1,782	Number 241 has arrived... the fun begins next week! __________________ Brian Western Massachusetts 08 Tundra Double Cab 5.7 TRD 93 FZJ80, locked, 4.6L, 6 speed, Orion <- now driving! 04 VW Touareg V8 w/ locker (hers) 80 FJ40 , 83k, PS and AC 05 Yamaha RS Rage Snowmobile 06 Suzuki King Quad 93 VW Corrado Syncro AWD 3.0L 51 Jowett Jupiter Roadster Last edited by bjowett; 08-15-06 at 04:29 PM.

08-03-05, 01:22 PM	#22
bjowett IH8MUD Lifer Join Date: Oct 2002 Posts: 1,782	The 1FZ has officially joined the 6 speed RA60 transmission. The mounting flange from the old A442 bellhousing was cut and removed, then TIG welded directly to the RA60 bellhousing. A few redundant steel braces will help support the weld... cast aluminum is cast aluminum, after the TIG is done, it can only be so strong. Centering the transmission to the engine was a slight challenge due to the fact that the RA60 uses no pilot bearing. A 3.5" long sleeve was machined and used in much the same way that a clutch alignment tool is used. The sleeve slides over the transmission's input shaft, and then slides into the pilot bearing hole in the crankshaft as the transmission is set into place against the back of the engine. Now on to machining the flywheel and adapting the Orion.... __________________ Brian Western Massachusetts 08 Tundra Double Cab 5.7 TRD 93 FZJ80, locked, 4.6L, 6 speed, Orion <- now driving! 04 VW Touareg V8 w/ locker (hers) 80 FJ40 , 83k, PS and AC 05 Yamaha RS Rage Snowmobile 06 Suzuki King Quad 93 VW Corrado Syncro AWD 3.0L 51 Jowett Jupiter Roadster Last edited by bjowett; 08-15-06 at 04:30 PM.

08-04-05, 05:53 PM	#23
lowtideride Ride On... Join Date: Sep 2003 Location: North Florida TLCA# 14891 Posts: 7,004	its about damn time yous 80s tech people stop talking about leather seats....awesome job bro __________________ www.NFCruiserheads.org 1983 SR5 Hilux... has had no peers for 50 years...

08-07-05, 10:44 PM	#26
bjowett IH8MUD Lifer Join Date: Oct 2002 Posts: 1,782	Yup... no pilot bearing is used. Just like the old front drive cable clutch VW's. The main shaft is very long and gear reduction is done on the output shaft side. All support is internal to the transmission. Nothing explains(??) it better than the picture of the shafts.... __________________ Brian Western Massachusetts 08 Tundra Double Cab 5.7 TRD 93 FZJ80, locked, 4.6L, 6 speed, Orion <- now driving! 04 VW Touareg V8 w/ locker (hers) 80 FJ40 , 83k, PS and AC 05 Yamaha RS Rage Snowmobile 06 Suzuki King Quad 93 VW Corrado Syncro AWD 3.0L 51 Jowett Jupiter Roadster Last edited by bjowett; 08-15-06 at 04:30 PM.

08-23-05, 02:00 PM	#27
MoJ Present Join Date: Oct 2003 TLCA# 14112 Posts: 2,708	Brian - How's the project going?

08-23-05, 09:12 PM	#28
bjowett IH8MUD Lifer Join Date: Oct 2002 Posts: 1,782	The shortblock is together and the flywheel is almost complete.... Flywheel chunk.... roughed in... Should have the final pic of it this week. __________________ Brian Western Massachusetts 08 Tundra Double Cab 5.7 TRD 93 FZJ80, locked, 4.6L, 6 speed, Orion <- now driving! 04 VW Touareg V8 w/ locker (hers) 80 FJ40 , 83k, PS and AC 05 Yamaha RS Rage Snowmobile 06 Suzuki King Quad 93 VW Corrado Syncro AWD 3.0L 51 Jowett Jupiter Roadster Last edited by bjowett; 08-15-06 at 04:30 PM.