78 fj40 , 1kz-te , h55f , orion

[beerfart]

78 FJ40 , 1KZ-te , H55f , Orion

This is my build thread on my 78 mustard fj40 I have been converting to a '95 1kz-te diesel from a hiace van . I've been working on it since september. Second photo shows the front of the 1kz auto bellhousing and the 40 clutch inside .

 

[beerfart]

Bellhousing

 

[beerfart]

Machined an flywheel insert disc for the pressure plate to bolt to out of a 1" thick steel disc . Press fit it in the 1kz flywheel and also bolted it together . Flywheel , insert , and clutch is almost 80 pounds . Flywheel and torque converter was about 60 lb.

 

[beerfart]

Balanced the flywheel and clutch .

 

[beerfart]

Made this adapter plate to mate a h55f to an orion . Close up of oil pipe and channels to catch oil and send to shaft bore .

 

[beerfart]

I bought a 1 meter piece of hardened 4130 12 mm all thread from mcmaster carr to make studs for the transfer case . I had to turn the threads off a section of one stud for gear ckearance . The two bolts on the lower right had to be counter bored for t case clearance .

 

[beerfart]

Mounted fj40 slave cylinder to bellhousing . The output bearing on the h55 is the exact size as the boss that protrudes into the tcase that is on the output of a h42 .

 

[beerfart]

This shows the part of the h42 that protrudes into the tcase . The h55 output bearing press fits into the tcase .

 

[beerfart]

Modified the input gear on the orion to fit h55 splines . second photo shows the stud with threads machined off for clearance .

 

[beerfart]

Didn't like the socket head bolt on the orion , so I used a stud and made this nut so I could get a socket on it .

 

[beerfart]

First photo shows counter bored bolt heads for tcase clearance , second photo is bearing I sourced for h55 output support in tcase . Same bearing , just bored larger . This one had grease seals , but I removed them .

 

[beerfart]

Orion bearing next to new h55 output shaft sized bearing .

 

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Checking the fit .

 

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Transmission mounts .

 

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Twins

 

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Motor mounts .

 

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Front drive shaft .

 

[beerfart]

Motor mounts .

 

[beerfart]

The driveshaft has a lot of clearance of the oil pan . The starter will hit the 40 steering box , so I had to remove it and installed an 80 series power steering . With the tcase in the origional location , the 5 speed shifter is in the perfect location .

 

[beerfart]

My tcase was to far to the rear for some reason . The splines were bottomed out , so I moved it forward about 3/8" , which made the front driveshaft splines perfect too . Many threads I have read say the h55 is too tall for a 78 tunnel . This is not true .