1993 FZJ80 Cummins 5.9 12v Swap

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B

bozilla

10 Year 15 Year
Joined
Jun 18, 2010
Threads
2
Messages
49
Hi there, I am new to posting and have been reading post on here for years. Figured I would start my build thread and add to the cummins 5.9 swap family. I bought my 1993 FZJ80 about 7 years ago, one owner and 90k miles on the engine. This truck has been an absolute dream to have. Installed a 2" old man emu lift kit, Borla stainless steel header back exhaust and been driving the heck out of it since. Now I have 128k on it and get about 8-10 mpg. Looking to take it cross county to camp and explore the county. Now decided several months ago to do the cummins 5.9 swap. I ordered Dustin's kit in November 2016 after reading many of the stories on here. Knowing it would take some time since he is basically making parts as he can. Took about 3 months, received all the parts, except what I have not yet sent him, torque converter and wiring harness. Excellent quality parts! In the meantime while waiting for the complete kit to come in, I decided to do a complete makeover, some light body work and paint, purchased a 1998 Dodge 2500 cummins 5.9 complete truck needing only the engine, having 190k on it and running great. Pulled both the 5.9 cummins and the land cruiser engine/trans/t-case and started preping for the swap. Another fellow swap brother was kind enough to send me Dustin's install instructions plus the several other builds on this site has certainly helped. I hope mine can help anyone else and hopefully between the pics and descriptions others may want to do this as well. Will post as I have things completed.

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That's where I am at so far. I'm certainly looking forward to the support from the rest of you guys who have more know how than myself and especially from those who have gone down this road before. Thanks in advance.
 
Today I was able to install new valve cover gaskets (clear coated the valve covers with high temp engine paint) , timing cover gasket with crank seal and painted the engine bay.

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Looks great!
 
Today I was able to tackle removing the rear seats to access the fuel pump. Removed the fuel pump from the unit and installed the pick up tube and reinstalled into the fuel tank. Also drilled out the filler neck to be able to use diesel nozzle at the pump. Picked up a skinny 19989-93 trans adapter plate on eBay and installed. Moving right along!

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When you go to mate the tranny and motor, get some long bolts, that fit the plate and cut the heads off, use this as an alignment tool to connect them, also kind of eye ball the, TC to flex plate bolts, when I did mine I used a 1" body lift, it helps to clear the fire wall and tunnel
 
On the drop tube for the fuel tank, use new hose clamps, the stock pinch clamps have dropped the tube, I have do several of these, and safety first :idea:
 
@shocktower thanks so much for the good advice and guidance on these steps, no doubt will certainly help! I did make use of the rubber cushion at the base of the old fuel pump, drilled a small hole in it and passed the pick up tube through and re seated. Seems really stable, however I definitely understand what you described. I just might install a hose clamp. Thanks!
shocktower said:
On the drop tube for the fuel tank, use new hose clamps, the stock pinch clamps have dropped the tube, I have do several of these, and safety first :idea:
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