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  1. 96TrailSurfer

    12/24V Switchover Relay - How does it work?

    Hi Everyone, Could someone explain to me how exactly the 12/24V relay works based on the FSM wiring diagram. As far as I can tell from the diagram: 1. + from the LH battery connects to the first (left hand) terminal on the 12/24 switchover relay and directly to terminal C on the starter 2. -...
  2. 96TrailSurfer

    Steering Problems After Lift and Frame Reinforcement

    So I am having more steering problems after installing new shocks, springs, adjustable panhard, Dobinson adjustable steering damper, and a steering box frame reinforcement kit (I moved the steering box aside but didn't disconnect it when I installed the kit). 1. Tough steering - feels almost...
  3. 96TrailSurfer

    Alignment and Steering Wheel Question

    Just finished installing new suspension and lift, including new front shocks, springs, adjustable panhard, and steering stabilizer, and now my alignment is (obviously) way off, including the steering wheel being about 130 degree off center (wheels face forward, steering wheel is almost a full...
  4. 96TrailSurfer

    Parking Brake Light Stays On?

    Just finished installing a major suspension upgrade and 4" lift (new shocks, springs, upper and lower control arms, adjustable panhards, a rear panhard raise bracket, SLEE extended brake lines, steering box frame reinforcement, and steering stabilizer), and now the parking brake light does not...
  5. 96TrailSurfer

    Help Identifying Panhard Bar and Bushings

    My HDJ81 came from Japan with an after-market dual-side adjustable panhard bar and a drop bracket. Can anyone identify the brand / model of this panhard bar so I can double check bushing size and determine if I can use an OEM bushing. My caliper measurement shows 38 mm ID, while I understand...
  6. 96TrailSurfer

    Tuning Mamba Turbo in situ ?

    I installed a mamba ct26 turbo on my 1hd-ft and realized that I didn’t adjust the preload correctly. Is there a way to change the preload without taking the turbo off?
  7. 96TrailSurfer

    3d files for 80 series

    Is there a thread with a collection or 3d files or links to 3d files for 80 series stuff?
  8. 96TrailSurfer

    EGR VSVs and Sensors Connected to Emission ECU

    Below is a wiring diagram for HDJ80, which I assume is the same as my 97 HDJ81. What I am looking for is the locations of the VSV (EGR) [3] and the Pick-up Sensor [4], as well as some info on what the pick-up sensor does. I know that VSV (EGR Cut) [1] and VSV (EGR Control) [2] are the VSVs...
  9. 96TrailSurfer

    HOWTO: AC Rotor (Pulley/ Clutch) Bearing Replacement In Situ (1HDT/FT)

    As our trucks get (quite) older, it's not uncommon to have the bearing go on the AC compressor rotor (pulley/clutch) assembly. When mine went on my HDJ81 (1HD-FT) the other day, I was surprised to find that most people recommended taking the compressor off to replace the bearing. That was not...
  10. 96TrailSurfer

    Wrong Torque for Leak Pipe Bolts in the FSM?

    1hd-ft FSM says that the torque for the hollow bolts that connect the leak pipe to then injectors is 18 Nm. Alas, I broke the bolt without even getting close to that torque. It the FSM is wrong as that’s way too much for those tiny bolts, or could it be that these bolts were stretched by...
  11. 96TrailSurfer

    Alternatives to the OEM Cylinder Block Insulator?

    The cylinder block insulator that sits behind the fuel pump on my 1HD-FT (12581-17010) has disintegrated. Amayama wants $100 for it with shipping. I know its not a huge amount, but still annoying for what appears to be a piece of thick foam. Are there any alternatives?
  12. 96TrailSurfer

    Fuel pump drive gear o ring (and why aren’t there any videos?)

    Taking out the fuel pump on my 1hd-ft, and the FSM says to take out the drive gear o ring, which I understand is the small one under the drive gear nut. For the life of me I can’t see it, it must be there as I can’t push the pump out with a puller. Any tips on how to get it out? And why...
  13. 96TrailSurfer

    How to remove fuel pump drive gear o-ring?

    Taking out the fuel pump on my 1hd-ft, and the FSM says to take out the drive gear o ring, which I understand is the small one under the drive gear nut. For the life of me I can’t see it, it must be there as I can’t push the pump out with a puller. Any tips on how to get it out?
  14. 96TrailSurfer

    Stuck Injector Seat

    I am having difficulty pulling out some of the injector seats on my 1HD-FT. Is there a trick to it?
  15. 96TrailSurfer

    SOLVED Help Identifying a Washer for 1HD-FT Injectors

    Hi, I am in the process of removing injectors and fuel pump from my 1997 1HD-FT to have them rebuilt. In the process, I found a cooper washer and can't find its proper place or find a diagram that refers to it. Please bear with me. Here is the washer beside an injector: I checked on...
  16. 96TrailSurfer

    Where did you mount your VHF/UHF radio?

    Folks with mounted shortwave radios (not the handheld units), where did you mount the base unit, the remote face plate (if any), and the microphone. On my Surf, I mounted the base unit under the passenger seat, and the face plate in place of the field monitor, with the microphone hanging down...
  17. 96TrailSurfer

    Is this supposed to be unplugged?

    I noticed that this sensor (blue plug), which appears to be a stock water temp sensor, is unplugged. Any idea if it’s supposed to be plugged in, and if so, where I could look for the connector? 1hd-ft
  18. 96TrailSurfer

    1hd-ft - What’s your boost without load?

    Folks with 1hd-ft with stock turbos, what boost do you get as your rev the engine without load (Park or Neutral), at what rpm, and how fast do you get there? I am trying to figure out if my turbo is having issues spinning up.
  19. 96TrailSurfer

    1HD-FT - Turbo Pressure Sensor and VSV

    Could someone kindly explain (or point to an explanation) for how the Turbo Pressure Sensor (3) works in conjunction with the VSV (5). Since there is no ECU, I thought that the TPS only controls the overboost light on the dash. But since it's paired to a VSV via a damper, is it the case that...
  20. 96TrailSurfer

    Help: 1hd-ft lost power / turbo does not spool up

    Hi Everyone, Hoping I can get some ideas for diagnosing and fixing this. 1hd-ft engine Went through a mud-puddle today and then lost all engine power. The best way to describe is that I flooring them gas pedal and get no response. If the vehicle is facing uphill, the only way to get it...
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