- Thread starter
- #101
The coating is one coat por-15 followed by two kits of Upol Rapter bedliner.
10/84 HJ47 Troopy Refurbish and Build Up
- Thread starter 1tontoy
- Start date
This site may earn a commission from merchant affiliate
links, including eBay, Amazon, Skimlinks, and others.
- Thread starter
- #103
HJ47 UPDATE! Out with the old Lump!
Like most of us, everything is a work in progress. And, for some of us, it takes years!
Finally, I dove into swapping out the good ole 2H/H41 for a 1HZ/H55 in the HJ47. The 2H has way over 500K kms and still ticking, and that's part why I haven't done this swap sooner... But, it's time. The new drivetrain is complete and ready to go in.
The 1HZ I picked up 2-3 years ago on MUD and I slowly rebuilt an H55 and splitcase that I had laying around.
The old lump and the new lump...
Like most of us, everything is a work in progress. And, for some of us, it takes years!
Finally, I dove into swapping out the good ole 2H/H41 for a 1HZ/H55 in the HJ47. The 2H has way over 500K kms and still ticking, and that's part why I haven't done this swap sooner... But, it's time. The new drivetrain is complete and ready to go in.
The 1HZ I picked up 2-3 years ago on MUD and I slowly rebuilt an H55 and splitcase that I had laying around.
The old lump and the new lump...
- Thread starter
- #104
It took me a while to disconnect everything. The actual extraction didn't take too long, except the "already replaced with s***ty castor" castor on the engine hoist broke while I had the engine half way out 
That sucked but wasn't too painful I was able to get a block of wood under the hoist's leg and replace it with a beefy castor.
Out you go! Thank you for your service and dependability for the last 29 years!
That sucked but wasn't too painful I was able to get a block of wood under the hoist's leg and replace it with a beefy castor. Out you go! Thank you for your service and dependability for the last 29 years!
- Thread starter
- #105
All the way out and put on a pallet. I plan to swap the tcase e-brake setup onto the new drivetrain. Also being added is OEM powersteering because the 1HZ has the pump built in.
Next will be removing the engine brackets from the frame and cleaning up the area...
Next will be removing the engine brackets from the frame and cleaning up the area...
What are you going to do to the engine bay while it's empty?
Prolly wish he was done already!, thats what!
Well, if it was you Kevin I know you'd make a new tub, fenders, grille and hood out of 14ga stainless in your spare time. I'm just wondering what a mere mortal will do... 
- Thread starter
- #109
No Kidding, especially with it getting dark early and I do all this work by myself (like you do) in my little ass driveway, it's a little daunting of a task. I hope to get alot done over the holidays.
Well, if it was you Kevin I know you'd make a new tub, fenders, grille and hood out of 14ga stainless in your spare time. I'm just wondering what a mere mortal will do...
Ya, for us "mortals", I plan to CLEAN, CLEAN, CLEAN the firewall and detail some of the parts.
And, I plan to use OEM HZJ7* frame-side engine brackets that I sourced new out of Japan and hope to utilize the stock trans mount location as the guide for installing the engine brackets.
I might need to move the transmission cradle brackets further rearward a bit.The brake booster and M/C will be gone through and possibly replaced with new units.
- Joined
- Sep 28, 2002
- Threads
- 558
- Messages
- 8,123
- Location
- Kamloops, BC Canada
- Website
- www.shopraddcruisers.ca
Many many years ago when I installed a 1hz into a FJ45, the engine was about 3 inches off the fire wall, did not impede the brake master?
Edit, I realize now you are RHD...
Rob
Edit, I realize now you are RHD...
Rob
- Thread starter
- #111
Engine Brackets Removed
Made a little more progress on the engine swap.
Ground off the studs on the old engine brackets and managed to remove them without much damage. When I pulled the 2H, one of the rubber engine isolators was completely broken and the other was pretty worn.
Made a little more progress on the engine swap.
Ground off the studs on the old engine brackets and managed to remove them without much damage. When I pulled the 2H, one of the rubber engine isolators was completely broken and the other was pretty worn.
- Thread starter
- #112
1HZ in it's new home
Got the 1HZ/H55 in it's position. I bolted the transmission cradle and rubber mount to the trans once it was under the truck. Then, used a jack and the hoist to set the trans. cradle down in the stock position - the cradle sits on top of the brackets (unlike a 60 series, for example).
I removed the shift cover and that helped alot.
Test fitted the radiator mount. And the fan shroud looks like it will work turned upside down.
Got the 1HZ/H55 in it's position. I bolted the transmission cradle and rubber mount to the trans once it was under the truck. Then, used a jack and the hoist to set the trans. cradle down in the stock position - the cradle sits on top of the brackets (unlike a 60 series, for example).
I removed the shift cover and that helped alot.
Test fitted the radiator mount. And the fan shroud looks like it will work turned upside down.
- Thread starter
- #113
Mocked up engine brackets
After cleaning up the frame rails, I determined roughly where the new engine brackets would be located. One of the large holes on the inner frame rail is where the engine bracket needs to be welded to. So, I made some plates out of 1/4"x12"x4" steel and trimmed them to the contour of the frame rail (it tapers down to smaller dimension as the frame goes forward).
Mocked it up with the brackets and isolators and basically set the engine down in final position to line up the brackets perfectly. They'll get welded up tomorrow morning.
After cleaning up the frame rails, I determined roughly where the new engine brackets would be located. One of the large holes on the inner frame rail is where the engine bracket needs to be welded to. So, I made some plates out of 1/4"x12"x4" steel and trimmed them to the contour of the frame rail (it tapers down to smaller dimension as the frame goes forward).
Mocked it up with the brackets and isolators and basically set the engine down in final position to line up the brackets perfectly. They'll get welded up tomorrow morning.
A tip tho a little late for use. An air chisel and air punch make quick work of the frame rivets. Hearing protection is required. Looking great. Nice to see it coming together to provide you with many more years of faithful service in the future.
Sent from my phone using IH8MUD
Sent from my phone using IH8MUD
- Thread starter
- #115
Battery Tray, Fuel Filter, Clutch slave
Made a bracket to mount a fuel filter - the 2H has the filter built into the injection pump. The 1HZ has a remote location. Plus the IP's are on different sides. I'm bending new hardline and running new biofuel rated hose from the OEM water separator to the IP.
Moved the battery to the other side using a BJ42 bracket. Fits nicely and the frame already has most of the needed holes for mounting it. Still need to extend the wiring.
Moved the plumbing for the clutch slave cylinder to the other side. Made a bracket to adapt the hose to the new hardline.
Also replaced the timing belt, cover and gasket, and belt tensioner.
Made a bracket to mount a fuel filter - the 2H has the filter built into the injection pump. The 1HZ has a remote location. Plus the IP's are on different sides. I'm bending new hardline and running new biofuel rated hose from the OEM water separator to the IP.
Moved the battery to the other side using a BJ42 bracket. Fits nicely and the frame already has most of the needed holes for mounting it. Still need to extend the wiring.
Moved the plumbing for the clutch slave cylinder to the other side. Made a bracket to adapt the hose to the new hardline.
Also replaced the timing belt, cover and gasket, and belt tensioner.
Three at once........sweet.
- Thread starter
- #117
UPDATE!!
The drivetrain swap is officially complete. I am absolutely stoked with the outcome.
The swap includes adding H55 with proper top cover, PS with RHD HJ61 steering box and 70 series linkage, BJ42 battery bracket, BJ42 throttle cable, BJ42 air cleaner housing with lid merged with 1HDT lid. And, I built my own SS 3" exhaust. Lowered, FJ55 radiator support with homemade fan shroud and new FJ40 4 core copper/brass rad.
I definitely hit some hurdles and learned a freakin' ton along the way. And, still need to do something for a parking brake. The sound with the turbo and straight pipe is sweet. Next up is scrapping the roof rack and ladder and replacing with something built out of aluminum and FJ60 diffs.
The drivetrain swap is officially complete. I am absolutely stoked with the outcome.
The swap includes adding H55 with proper top cover, PS with RHD HJ61 steering box and 70 series linkage, BJ42 battery bracket, BJ42 throttle cable, BJ42 air cleaner housing with lid merged with 1HDT lid. And, I built my own SS 3" exhaust. Lowered, FJ55 radiator support with homemade fan shroud and new FJ40 4 core copper/brass rad.
I definitely hit some hurdles and learned a freakin' ton along the way. And, still need to do something for a parking brake. The sound with the turbo and straight pipe is sweet. Next up is scrapping the roof rack and ladder and replacing with something built out of aluminum and FJ60 diffs.
How well is the Upol holding onto the POR as a base coat? I thought POR was not intended to be top coated, or at least nothing sticks very well to it. Curious to hear your thoughts. Super nice engine swap! Very well done.
Fantastic! I'm envious and happy for you all at once.