My 3FE into FJ40 swap (1 Viewer)

[Curtice]

Creating this thread to document my FJ40 conversion to a 3FE. Also, since I have never worked anything close to this big on my cruiser before, I need a good place to ask all of my questions...there will be a lot, and many of them pretty basic probably. I have a good friend who has been very helpful so far (thanks Scott ), but I don't want to keep bugging him every day to answer every little question I have.

I also hope this thread will be helpful to other people doing a similar conversion who are rookies to this type of thing like I am. A lot of the information out there assumes a certain level of knowledge which I don't often have.

My biggest fear is putting everything together only to find out later I did something wrong and have to take major things apart. Just take it slow I guess.

I welcome all comments and tips on anything I am doing.

A little background. Its a 1980 FJ40 that I have had for about 12 years. It sat in a garage for most of that time, until I decided to revive it a while back. Did a bunch of body work paint job about 2 years ago. Also other work including new suspension, steering parts including mini-truck conversion.

Here is a picture after that work:

(I sold the hard top this summer and am awaiting a soft top.)

Late this last summer, had some engine problems. Not sure yet what happened, but I know its bad. Engine knocked all over the place, and now will not even start. So faced with the decision to rebuild or swap a new engine in, I got a line on a rebuilt 3FE. So decided to go that route. Once I am done with this project, I want to learn how to rebuild the 2F, so will work on that.

Here is where I am now. I have pulled the 2F and removed the bellhousing, flywheel, and clutch components to reuse with the 3FE. But I will likely purchase new clutch disc and plate while I have it apart. Also while I have things apart, dropped the transmission/tcase and in the process of cleaning up a bit. I also have all of the wiring pulled from the engine and behind the dash. As wiring is a huge part of this conversion, I am taking the opportunity to clean it all up, since things have always been sketchy.

While I have things apart, I plan to do the following side jobs:
Amaurer gauge upgrade
Clean and repair existing wiring that I will continue to use
New battery and starter cable
Clean and paint transmission, bellhousing, and skid plate
New clutch disc and plate
New parking brake cable (since my original is not in good shape)

Couple pics of the 2F removal:

As we were lifting it out, realized I wouldn't get the clearance to lift the engine over the frame because of the garage door. So had to set it one some 2x4's and adjust the chain shorter. It barely made it.

Cleaned up the engine bay a bit. Thought I might take this time to paint the firewall, but decided not to.

And cleaning the transmission/tcase. A lot of oven cleaner and washing. The oven cleaner didn't seem to hurt the aluminum, but I didn't leave it on very long. While it still looks dirty, it is 100x better than when I pulled it.

 

[Curtice]

Post #2 - A few random tips and pointers that I learned as I did this...maybe common knowledge to some, but I didn't know

1) My engine didn't have hooks for the hoist, so I threaded a head bolt through a chain link. The bolt was a bit too big, so I put the chain link in a vice and widened it slightly. I attached to the head bolt on the front passenger side and rear driver side.

2) I used a load leveler and was glad I did...it was very helpful to be able to shift the weight around as the engine was maneuvered.

3) I disconnected the transmission at the bellhousing while still underneath the vehicle. It was only 4 bolts and came apart quite easily. I think this made pulling the engine much easier. I supported the transmission with a cheapo HF tranny jack, since my cruiser did not have a transmission support aside from the rear engine mounts (I think that wasn't until later in 1980). Still trying to decide if I want to mate the transmission to 3FE before or after installing the engine.

4) To remove the bellhousing, had to remove the clutch and flywheel. There are 6 bolts to remove the bellhousing, 4 of which are behind the flywheel. To remove all the bolts for the clutch plate, I had to rotate the flywheel to get access to each of them below the bellhousing. To turn the flywheel, I rotated the big bolt on the front of the engine.

5) If you have to detach the speedometer cable, disconnect it at the transmission end first....sooo much easier.

There are probably more. As I think of them or come across them, I will update this post.

 

[Curtice]

Post #3 - Information and parts obtained Other forum threads that I found helpful and will refer to often:
https://forum.ih8mud.com/60-series-wagons/325371-3fe-efi-primer-knowledge-pool.html
https://forum.ih8mud.com/40-55-series-tech/204043-3fe-fj40-rtcustoms-build-1.html
https://forum.ih8mud.com/40-55-series-tech/719574-3f-e-conversion-thread.html
https://forum.ih8mud.com/60-series-wagons/518581-3fe-conversion-write-up.html
https://forum.ih8mud.com/40-55-series-tech/204049-correct-speed-sensor-vss-info-3fe-swap.html
https://forum.ih8mud.com/40-55-series-tech/206265-cruiserparts-net-drop-3fe-fj40.html
https://forum.ih8mud.com/ks-mo-tornado-alley-cruisers/87357-3fe-conversion-fj40.html
https://forum.ih8mud.com/40-55-series-tech/271696-3fe-40-what-fuel-pump-cross-post.html
Smog info: http://www.ih8mud.com/tech/pdf/3FE-Desmog_Guide.pdf

I am referring heavily to the infamous conversion guide from pappy that is all over the internet. One version here: http://bushrat.hdcruisers.org/3FEconversion.pdf.

I also obtained an FSM for a 1989 FJ62 (from whence my 3FE came originally) to go along with my FJ40 manuals. I am waiting to get the engine this weekend to determine everything I will need. I think it will come with the ECU and related connections and sensors. I do already plan to purchase the following:

FJ62 wiring harness(es)
New PS lines since the pump is on the other side of the engine on a 3F
Fuel pump (and filter)
new motor mounts
FJ62 gas pedal and throttle cable

After I get the engine and sort out what I have/dont have, this list will grow much bigger, I am sure.

 

[Curtice]

First question. I have two sets of wires on the transmission. One is two wires with bullet connectors that I think is reverse light switch. But does anyone know what this other wire/connector is for?

 

[77TLCFJ40]

First question. I have two sets of wires on the transmission. One is two wires with bullet connectors that I think is reverse light switch. But does anyone know what this other wire/connector is for?

Some emissions BS. Are you still smogged?

 

[tornadoalleycruiser]

1978 ish tranny nss thing.

Sent from my SAMSUNG-SGH-I537 using IH8MUD

 

[Curtice]

I am smogged, but I don't think that was hooked up. Thanks.

 

[matt.mcinnes]

Ill ask the age old question but why not build a 2FE using the old 2F block?

 

[73tlcv8]

x2 neutral start switch

 

[Curtice]

Ill ask the age old question but why not build a 2FE using the old 2F block?

A few reasons. The 3FE was recently rebuilt, so it is in good shape. I am a rookie at this stuff, so this seemed easier than rebuilding an engine and modifying it for a 2FE. I do want to rebuild the 2F, but want to be able to drive my cruiser while I figure that stuff out. Maybe I will rebuild the 2F to a 2FE and put it in my next cruiser

 

[meatloaf]

I'll be keeping an eye on this post since I am also doing a 3FE swap.

 

[Curtice]

x2 neutral start switch

What does the nss do? Does it cut off power to the starter if not in neutral?

 

[tornadoalleycruiser]

If you had the correct jumper wire yes. Only have seen one truck with it correctly wired. Cant start in gear. Id rather be able to start in gear.

Sent from my SAMSUNG-SGH-I537 using IH8MUD

 

[srgould41]

Nice looking 40! I'm surprised I am the first local Cruiser Head to reply. There are a bunch of us 40 addicts close by who would love to drink your beer and give advise or maybe even help out. Check out the group (we aren't a club) using my signature links, unless you already are a CruiserHead and I'm just not remembering your truck. I do that a lot

 

[matt.mcinnes]

A few reasons. The 3FE was recently rebuilt, so it is in good shape. It's coming out of a 40, so is "plug and play", as much as is possible anyway. I am a rookie at this stuff, so this seemed easier than rebuilding an engine and modifying it for a 2FE. I do want to rebuild the 2F, but want to be able to drive my cruiser while I figure that stuff out. Maybe I will rebuild the 2F to a 2FE and put it in my next cruiser

I was a Rookie once and look where I ended up on my first build

Good luck with the build you will learn much.

 

[Curtice]

Nice looking 40! I'm surprised I am the first local Cruiser Head to reply. There are a bunch of us 40 addicts close by who would love to drink your beer and give advise or maybe even help out. Check out the group (we aren't a club) using my signature links, unless you already are a CruiserHead and I'm just not remembering your truck. I do that a lot

Thanks. I have met a couple of you guys over the summer. I have wanted to hit some of the gatherings, just always so busy in the evenings. No doubt sooner or later I will hit up the group for some help...bound to get stuck at some point

 

[lelandEOD]

I just went through this conversion recently. Check out my 3FE conversion thread too. You may pick up something useful.

https://forum.ih8mud.com/40-55-series-tech/719574-3f-e-conversion-thread.html

I love your truck too. Good luck!

 

[Curtice]

I just went through this conversion recently. Check out my 3FE conversion thread too. You may pick up something useful. https://forum.ih8mud.com/40-55-series-tech/719574-3f-e-conversion-thread.html I love your truck too. Good luck!

Thanks. I have read your thread! Good stuff, I wish I could memorize it all. I read all this good stuff, then forget.

Just picked up the motor and loaded it in the back if the truck. Put it in a tire and strapped it down.

It looks great. The entire ECU harness is still all hooked up. I am hoping it will be basically plug and play, as far as wiring passenger side goes.

Detailed pics to follow later today.

 

[73tlcv8]

The 3fe ecu uses the Park/Neutral switch as an input. Most if not all of us with M/T just connect these wires together in the ECU harness so it thinks it is always in park.

 

[Curtice]

Does anyone have a picture or can explain how this linkage is supposed to be on the tcase? It was like this when I removed it, but I think there should be bolt or something going through that C shaped piece?