3FE Dual battery setup, using an FZJ tray

[Lka1988]

This idea was inspired by Trailbus, who did a dual battery setup in his 91 FJ80 but didn't do a writeup... Greg, I'm FINALLY doing it

So, as many of you who own 91-92's know, the battery tray is mounted on the passenger side of the engine compartment, opposite to the FZJ. FZJ owners have it easy as far as dual battery setups go, all you guys have to do is relocate the windshield wash fluid reservoir to make room for an FJ tray.

However, the 91-92 FJ owners don't have it so easy. In the driver side corner, where an FZJ tray goes, there is a plethora of stuff, including but not limited to, emissions components and a cooling fan. This poses a problem for guys wanting to do a "proper" dual battery setup in their FJ's, at least to the guys who have emissions laws in the area.

Over the next while, I'll be installing a proper dual battery setup in my 91. I'll be using a tray from a 1994 FZJ.

Stay tuned...
-Lane

 

[Lka1988]

parts

Editor's note: Not many parts need to be added, more parts actually need to be removed...

I will update the parts list throughout the process.

-1994 Battery Tray, 74043-60010
-Small length of copper tubing, to splice two hoses together
-Hose clamps

 

[slow91fj90]

Cool idea, this is what I did.

https://forum.ih8mud.com/80-series-tech/205363-different-option-dual-batterys-3fe.html

 

[Lka1988]

So far so good.

All the stuff that was in the way...

All gone now!

 

[Lka1988]

The smog pump valve, before modification.

I also had to cut the bracket that held the smog pump valve in place, in order to fit the tray.

Cut-off part of the bracket.

 

[motorsargeT]

I did the same thing, but I ditched the smog pump and all it's associated plumbing at the same time. I also temporarily added a 3 inch Marine blower to replace the carb cooling fan. Temporarily as in 5 years ago.

 

[Lka1988]

smog pump valve modification

Since we cut off the bracket, the smog pump needs to be relocated in order for the tray to fit.

Before modification:

After modification (pics by Trailbus):

Trailbus also made a bracket to keep the valve stabilized, but the valve will hold itself without the bracket.

 

[Lka1988]

tray

The tray took some time to fit properly, had to trim it to fit behind the radiator and a bit to fit next to the wash reservoir.

Ignore the red conduit going across the tray.


Tray fitted

Trimmed here and here...

 

[Fergie]

Any more on this? How has everything worked for you?

 

[Lka1988]

Wow, I totally forgot about this... I initially made the thread to show how to retrofit an FZJ tray into an eariler FJ, but I guess I can update it.

I'll get some pics later today.

 

[lt1fire]

What type of dual battery system did you go with?

 

[Lka1988]

Just a Surepower isolator from Checker Auto. Rocky Mountain Power uses them in their fleet trucks, so they can't be THAT bad.

 

[Lka1988]

More pics.

Battery installed

Surepower isolator

More space!

 

[80t0ylc]

Just a Surepower isolator from Checker Auto. Rocky Mountain Power uses them in their fleet trucks, so they can't be THAT bad.

How do you like your Surepower isolator, Lane? Yours must be a different model than mine. My terminals are all in a row instead of diamond shaped like yours. Mines a model 12023A from NAPA.

I use mine exclusively for the winch. I haven't gone crazy on aftermarket electronics, so my main battery handles everything else. I decided to put a disco switch in the charging lead right at the + terminal of the 2nd batt. I was using the winch one time and the batt. was near flat and the solenoids started chattering and popped my ignition fuse. Went right through the isolator. I was lucky that was all that happened. So I figured I'd disco battery when winching to help stop me from frying my stock wiring or components. I might have an issue with the winch solenoids, but I'll figure it out eventually. Here's a couple of pics of my isolator and disco switch on 2nd batt:

 

[Fergie]

Have you had any issues with the removal of the extra fan?

Looks good BTW.

I've got the tray ordered from the dealer, so soon, very soon I'll have my NL kit installed.

 

[Lka1988]

How do you like your Surepower isolator, Lane? Yours must be a different model than mine. My terminals are all in a row instead of diamond shaped like yours. Mines a model 12023A from NAPA.

I can't remember what the model number is, but it was the $35 special. Works great.

 

[Lka1988]

Have you had any issues with the removal of the extra fan?

Looks good BTW.

Not that I'm aware of.

I need to clean it up a bit and get some better terminals for the isolator. The current terminals are shaped weird and VERY close to each other... If you can't tell...

 

[Fergie]

I dunno, the hose takes care of the proximity issue.

Did you use stock fuseable links on the second battery?

 

[Lka1988]

I dunno, the hose takes care of the proximity issue.

Did you use stock fuseable links on the second battery?

Nope. Actually, there is no fuse on the second battery... I should fix that, huh?

 

[Fergie]

Nope. Actually, there is no fuse on the second battery... I should fix that, huh?

No clue, it looks as though the little link container is near the isolator in the pic.