1HD-FTE Conversion - Creating my perfect 80 Series
- Thread starter MooseMichaels
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- Thread starter
- #122
Current status:
Things to do:
Things to do:
- Receive and install conversion harness
- Receive 1HZ low pressure ac line
- Then finish installing front clip
- Receive and install HDJ80 lower radiator hose
- Receive and install new auto trans and t-case shift boots
- Connect t-case and auto trans shift linkages
- Re-install t case skid plate, front sway bar, and drive shafts -this will happen after harness is installed so I have easier access.
- Install lutz auto multi gauge
- Put interior back together.
- Double check all fluids, check again.
Hell yeah! Lets gooooo!The light at the end of the tunnel is there and I can already smell the diesel burning.
- Thread starter
- #124
Small, but huge update - Jonathan has completed my harness, and sent video of it running his FTE/80 truck, with live OBD reads. Will be shipping out this week! 
I didn't love how the FTE low pressure power steering line to the vane pump was contacting the steering box after installing the engine, so I re-clocked the connector 15 or 20 degrees clockwise on the pump by welding on some more "ear" to the hose barb mount plate, and drilled a new hole for the bolt, then paint. Waiting on a new o-ring to arrive for this connection. Also waiting on a number of other parts.
I hope to have this thing making some good noises in the next 3 weeks or so.
I didn't love how the FTE low pressure power steering line to the vane pump was contacting the steering box after installing the engine, so I re-clocked the connector 15 or 20 degrees clockwise on the pump by welding on some more "ear" to the hose barb mount plate, and drilled a new hole for the bolt, then paint. Waiting on a new o-ring to arrive for this connection. Also waiting on a number of other parts.
I hope to have this thing making some good noises in the next 3 weeks or so.
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New O-rings? Cant hide money.
haha. Good progress, when you get your harness we need to make a thread to compare them.
haha. Good progress, when you get your harness we need to make a thread to compare them.
- Thread starter
- #126
I know, I can't help myself, my last $3 went 
- Thread starter
- #127
Parts arriving today, some fluids going in.
Spent last night in the dark working in the void, dreaming up some mounting locations for the fuel return line damper, and vacuum reservoir. I have locations planned, and made some mounts, waiting for paint on them to cure. I wanted these to be in a location that didn't require drilling holes anywhere, allows serviceability, minimum of two points of contact and not in the way of simple maintenance items like the oil filter.
Spent last night in the dark working in the void, dreaming up some mounting locations for the fuel return line damper, and vacuum reservoir. I have locations planned, and made some mounts, waiting for paint on them to cure. I wanted these to be in a location that didn't require drilling holes anywhere, allows serviceability, minimum of two points of contact and not in the way of simple maintenance items like the oil filter.
I did some research and ended up not using the fuel return damper ,i also somehow bent the inlet while pulling the FTE . I wonder how much of a difference it makes with injection pump noise. This is what the manual says about it lol.
Im excited to see what you come up with for mounting everything, it looks like yours has a secondary fuel filter? Is that from Government/Middle Eastern Specs?
Im excited to see what you come up with for mounting everything, it looks like yours has a secondary fuel filter? Is that from Government/Middle Eastern Specs?
- Thread starter
- #129
Mounting will be in the locations they're shown in the photo - fuel damper will be at a 45 degree angle, and will square up the vac reservoir.
I did a little reading on the fuel pulse damper also, and it seems it's just an empty volume inside, and is meant to reduce NVH / harmonics in the fuel return line from the injectors at certain rpms/frequencies. That's about all I know about it. I figured let's go ahead and use it since I have it, trying to stick to the philosophy of making things as OE as I can.
Yep, this one had the pre-fuel filter which I thought was really nice, and OE filters for it are readily available. Doing some reading on the pre-filter matches your thoughts, seems like it's typically included for desert/dusty environments. This came from a cruiser that was government owned in Guam, so my best guess is that the DoD ordered up the most rugged spec the could - no EGR, extra filters, etc.
That's what I would do if I had the job of ordering vehicles for an organization, except every vehicle in the fleet would be a 70 series
I did a little reading on the fuel pulse damper also, and it seems it's just an empty volume inside, and is meant to reduce NVH / harmonics in the fuel return line from the injectors at certain rpms/frequencies. That's about all I know about it. I figured let's go ahead and use it since I have it, trying to stick to the philosophy of making things as OE as I can.
Yep, this one had the pre-fuel filter which I thought was really nice, and OE filters for it are readily available. Doing some reading on the pre-filter matches your thoughts, seems like it's typically included for desert/dusty environments. This came from a cruiser that was government owned in Guam, so my best guess is that the DoD ordered up the most rugged spec the could - no EGR, extra filters, etc.
That's what I would do if I had the job of ordering vehicles for an organization, except every vehicle in the fleet would be a 70 series
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- Thread starter
- #130
Also, I started wrestling the shift linkages / levers into place. I'll need to do a little adjusting to clearance all the linkages, now that I can cycle each lever while in place.
I replaced the lower seal / boot because the original was cracked, typical "while you're in there" scope creep.
I replaced the lower seal / boot because the original was cracked, typical "while you're in there" scope creep.
- Thread starter
- #131
Ok, got the vacuum reservoir and fuel pulse damper fully mounted and plumbed up.
And shift linkages set up, I can mechanically get into all gears with the t-case in both low and high range. Sweet.
And shift linkages set up, I can mechanically get into all gears with the t-case in both low and high range. Sweet.
Looks good man! Harness make it yet?
- Thread starter
- #133
Not yet, Jonathan is shipping it out Tuesday. So should be here around a week from Tuesday is my guess until I get some tracking info. Still stoked. I'v been knocking out a bunch of small projects to keep momentum. When the harness does arrive, all I should need to is work through getting it installed and sorted out, then stick the hood back on.
Gettin' close!
You are going to love it sooooomuch.
The FTE/A750F blows the four speed diesels out of the water.
You are going to love it sooooomuch.
The FTE/A750F blows the four speed diesels out of the water.
I think my next one will be a FTE/A750F. The manual is cool, but I'd like to have a auto 79 series at some point.
- Thread starter
- #136
Super close for sure! The folks in the 100 series section seem to like late model 100’s for improvement with the A750F (among other things). Looking forward to seeing what it’s all about with an FTE in front, sitting in an 80.
- Thread starter
- #137
While waiting on parts, I shifted gears and installed a tile backsplash and replaced a dishwasher. Still needs caulking/silicone.
I much prefer wrenching in the garage vs screwing around with dishwashers.
Ok, back on topic, I picked up a new speedo sensor shaft seal and o-ring from the dealer, as it was weeping gear oil just a bit. Nice to find the leak that was causing the transfer case to be so grimey.
I had a family member who is a solid TIG welder merge the 1HZ ac line with the 1FZ line, then leak test. The condenser side of the line is from the 1FZ line, and the rest is the 1HZ line, which fits up nicely and looks OEM.
I finally put the rest of the front end back together with the AC line installed. That’s a friendly face I haven’t seen in a while.
Lastly, the conversion harness from Jonathan arrives TODAY. I’m planning to work on the 80 all weekend, and hope to be posting some good news and first starts.
I much prefer wrenching in the garage vs screwing around with dishwashers.
Ok, back on topic, I picked up a new speedo sensor shaft seal and o-ring from the dealer, as it was weeping gear oil just a bit. Nice to find the leak that was causing the transfer case to be so grimey.
I had a family member who is a solid TIG welder merge the 1HZ ac line with the 1FZ line, then leak test. The condenser side of the line is from the 1FZ line, and the rest is the 1HZ line, which fits up nicely and looks OEM.
I finally put the rest of the front end back together with the AC line installed. That’s a friendly face I haven’t seen in a while.
Lastly, the conversion harness from Jonathan arrives TODAY. I’m planning to work on the 80 all weekend, and hope to be posting some good news and first starts.
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Can't wait for the first start, side note I have to call PDI and see if I can get the WITH crossover pipe, and stock Turbo.While waiting on parts, I shifted gears and installed a tile backsplash and replaced a dishwasher. Still needs caulking/silicone.
I much prefer wrenching in the garage vs screwing around with dishwashers.
View attachment 4012159
Ok, back on topic, I picked up a new speedo sensor shaft seal and o-ring from the dealer, as it was weeping gear oil just a bit. Nice to find the leak that was causing the transfer case to be so grimey.
I had a family member who is a solid TIG welder merge the 1HZ ac line with the 1FZ line, then leak test. The condenser side of the line is from the 1FZ line, and the rest is the 1HZ line, which fits up nicely and looks OEM.
View attachment 4012163
View attachment 4012167
View attachment 4012168
View attachment 4012170
I finally put the rest of the front end back together with the AC line installed. That’s a friendly face I haven’t seen in a while.
Lastly, the conversion harness from Jonathan arrives TODAY. I’m planning to work on the 80 all weekend, and hope to be posting some good news and first starts.
I like to camp quite a bit in the cold so its probably time I get on that. Are you keeping the grid heater?
- Thread starter
- #139
No, Jonathan and I decided not to keep the wiring for the grid heater in the harness - seems like it's a huge amount of load on the battery/alt, and is often not needed. Where I live, they salt the roads in the winter, and with the 80 being a clean, Arizona example, it's certainly not going to see salt for the first time under my ownership. So likely not a whole lot of cold starting. Physically, the grid is still present, but I'll likely remove it from the cross over as continue to get things sorted.
For the PDI setup with the crossover piping, it appears just be two silicone couplings, and the big L-shaped pipe - I'm sure they'd be able to send you just those.
For the PDI setup with the crossover piping, it appears just be two silicone couplings, and the big L-shaped pipe - I'm sure they'd be able to send you just those.
Yeah I kept all the wiring for the grid heater from the HDJ100, so it would be interesting to get going.
I may be overthinking about the cold starts considering i wouldn't be parked for days without starting in the cold. I'm about to fluid film the s*** out of mine to prevent rust for the winter.
We'll also see how hard Colorado decides to screw me when I go to get emissions done, I may need the crossover so it "Appears" I have an EGR.