2FE crowbar needed...

[Jerry D.]

I have a ’68 FJ40 with an ’81 2F in it and I am now installing a 3FE head/EFI onto the block. Problem is the intake will not clear the brake booster. Prior to starting this mod, I read many threads on the subject, a few noted very tight fit/clearance. One even commented about moving the engine over.

My intake and brake booster are about a one inch overlap. The booster I have been using is from an ’82 FJ40 and is duel diaphragm 8 ½ inches wide, and it barley touches the clutch master cylinder. From the mounting studs of the booster to the side is a distance of about 2 ½ inches. Clearance from the mounting hole on the firewall is about 1 ½ inches to the intake tube. (See first picture, looking down, second from front. Third is stud to edge of booster body.)

Moving the engine over would be quite a chore as I have a Toy Box and rear transfer case brace.

Are there any alternatives to a smaller diameter Toyota booster, about 7 inches that can handle four wheel disk and the weight of the Cruiser???

Thanks,
Jerry D.

 

[Fast Eddy]

Use a smaller booster. The one out of a '91-ish 4runner is very low profile and wide and provides plenty of boost.

You'll gain 3-4" of clearance for about $35 at the junk yard. Don't forget to get the inline check valve. Bonus is that you can probably get $75+ for the one you have in the classifieds.

 

[LAMBCRUSHER]

the inside/outside bolt patterns changed in 95 on those runners......anything from 86-94 should do the trick. some of them have spacers or plates at the nfirewall, so make sure you get that too. and the vacuum check valve on those runners is divorced from the booster, so also make sure to get that. What about clocking the motor by adding blocks to the drivers side engine/tranny mounts???

 

[SteveH]

The Geo Metro brake booster has been used by some. The other fix is to swap in the late model firewall, whose booster spot is moved 3" closer to the driver's side.

 

[Fast Eddy]

some of them have spacers or plates at the nfirewall, so make sure you get that too.

I have a spacer that I never used. They're very thick. Both of mine have an extra set of nuts between the booster and the firewall to space it out a bit.

 

[reddingcruiser]

Hydroboost brake set-up.

 

[Fast Eddy]

Hydroboost brake set-up.

Eew. Too many lines running all around. Ok for a diesel, maybe. When they go out they fail strangely and are messy to replace. :thumbsdown:

 

[reddingcruiser]

I don't have a hydroboost brake system but I know guys that do and they've never had a problem (certainly not in the stopping department!). I don't think the failure rate is any higher than that of a standard brake system - and there are literally tens of thousands of them on the roadways in meduim duty trucks, hauling much more weight than an FJ40.

 

[40TUDE]

I used one out of 1991 80 series

 

[tucker74]

The '75-'76 booster is much slimmer than the '77+, I didn't have any clearance problems in my '76 w/ the 3FE swap. Not sure if you can still get these new ... might be able to source a used one ?

Tucker

 

[3_puppies]

68 would not have been boosted in stock form. what mods were performed to mount the booster originally? it is hard to see the firewall, so is the rib there? is it cut? did you use a spacer?

 

[Jerry D.]

When I install the booster about 10 years ago, I cut the firewall brace, enlarged the center hole and four mount holes. The current booster just misses the clutch master, maybe by 1/4 inch. Also the '68 has the vacuum actuated T-case, putting another line close to the booster I have. There is no spaced with this booster.

All worked with stock two barrel carb, and a TBI set up. Booster has to down size, and that hydro boost sounds first class.

Here is a picture of the firewall and hole.

Thanks for the ideas so far, may have to wait for Isaac to pass before I can get to a junk yard.

Jerry D.

 

[handcannon]

X2 on the hydrobooster.

I have a 94 Chev diesel pickup and 97 and 98 Astro vans. All three have hydroboosted brakes and work great. The Astro van booster is smaller than the pickup booster.

Some of the Astro boosters I've seen in wrecking yards are angled downwards and might possibly be helpful with clearances. I don't know the bore size of the Astro brake cylinder, but just guessing I'd say they would be closer in size to the 40 than the pickup master. This would make it easier to adapt the Toy master to the booster, if you go that route. The pickups master is somewhere around 1 3/16" if my memory is right.

Don

 

[Jerry D.]

Thanks for the years and models, I plan to visit a yard tomorrow.

I have a few extra Toyota P/S pumps, so I may dedicate one to the hydro booster.

Jerry D.

 

[gom2109]

When I install the booster about 10 years ago, I cut the firewall brace, enlarged the center hole and four mount holes. The current booster just misses the clutch master, maybe by 1/4 inch. Also the '68 has the vacuum actuated T-case, putting another line close to the booster I have. There is no spaced with this booster.

All worked with stock two barrel carb, and a TBI set up. Booster has to down size, and that hydro boost sounds first class.

Here is a picture of the firewall and hole.

Thanks for the ideas so far, may have to wait for Isaac to pass before I can get to a junk yard.

Jerry D.
View attachment 667617

At the end how did you fix it?