2wd to 4x4 SAS 1986 Toyota Chinook camper build

[Matthes]

some info

Hi,

if you still hanging/debating with Lc 60 axles, look here:

https://forum.ih8mud.com/hardcore-corner/410733-just-another-suv.html

You will find there also a R151 with Splitcase( we have them here in Europe in LJ 70`s with 2Lt Engines) attached to a V8. Means there is plenty of space for all of this.

R151 with Splitcase uses not the same tailhousing like the "Turbominnirunner". But the Splitcase is the same used in the latest 60/61/62.

Matt

 

[Dedtruk]

I plan on dropping in the 4x4 tranny in the camper a week or so. I am using a W56 type from an 1990's 22re. I will post some pics up soon for positive ID. I need to order a clutch alignment tool and still up in the air about a new clutch. I know it is best to do it when the tranny is out but that is more $ and I am starting to run low on funds.

Do the clutch now. I swapped a complete motor/trans/case into my 88 mini back in 2005. The donor truck had about 140K on it. Originally, I planned on doing the clutch while the donor motor/trans/case were on the ground (easy access), but changed my mind because the donor truck drove fine. Left the new clutch kit and turned flywheel on the shelf. 88 drove fine too after the swap (around the block only) but then it sat until this year. I got it running again, put about 15 miles on it and the clutch started slipping, new clutch time. Great ... One of the bellhousing bolts absolutely refused to budge. Ended up boring a hole through the firewall. Sixteen hours of major slaving later, clutch is in, truck drove fine for two weeks and trans synchros went. Now I get to pull the trans again, yipee! Please do yourself a favor and do the clutch now!

And be sure to get the right clutch for your flywheel (discussion starts around post #116):

https://forum.ih8mud.com/79-95-toyota-truck-tech/458306-rebuild-replace-22re-specs-inside-6.html

 

[meigsrock]

Thanks for the advice. I will check out that thread. I have been looking at clutches. Any suggestions for a good clutch or brand. I was looking at the heavy duity listed on the trail gear web site and Marlin. I am leaning tward a heavy duity one because of the weight of the truck, towing, and that I am not driving it around town daily. I need to see what kind of $ I have and try to scrape together for one.

I also want to see what kind of condition the one in the truck is in. I have the replacement tranny in the garage and getting ready to put it in. I will post pics of it soon for ID but I think it is the same as the one in my 1992 so it should be a W56 style. Droping the old one out Sunday. I hope the new one is good. I am taking it on the work of the guy I got it from, but I am hopefull. I will have to fab on my cross member and that will take a little work. I will go into detail and post pictures of that once I get underway this weekend.

I am going to get all my fluids tomarrow before work so I am ready on sunday. Got the truck up on stands ready.

 

[meigsrock]

Matthes: I would love to do a set up like that but lots of those engine and tranny combos are non us so I would have a hard or expencive time finding them.


Here is some pictures of the tranny that I a swaping for the 2wd tranny. Pretty sure it is a w56-? series. It looks a lot like the one in my 1992 pickup. Shifters are the same. I need to look at my pickup with a mirror and see if the top shifter style is the same.

If anyone out there knows more please help me ID this thing. Is there any place to look for data #'s on it?

Old one comes out tomarrow, then I get to see what condition the clutch is in and how hard it will be to get it to fit on the cross member.

 

[meigsrock]

Here is a couple more of the tranny.

 

[Bogo]

Marlin Crawler has lots of identified transmission pics on line. Do you know what it came out of? That shifter boot sticks looks like the one in my '94 deluxe pickup that has a W56 behind a 22RE. BTW, the rest of the transmission and transfer case combination also looks very familiar. I don't know how to tell the W56 C/D/E variants apart other than by year of manufacture.

Edit: Just noticed the electronic speed sensor by the rear wheel output flange. It would likely be a D or E with E being more likely.

 

[meigsrock]

Yes it is a W56 but not sure what series or what year. It has the electric speed sensor on the transfercase for the spedo I think. The 2wd tranny has a spedo cable so I will have to figure out how how to get that to work.

I got all the bolts out and the tranny partly dropped. The crossmember is welded in and will not drop so that is the hold up now. What a f ty design. I think I am going to have to unbolt the pressuer plate to get the tranny to drop.

Really makes me want to do a SAS all at once and cut the thing out. I am thinking of using the landcruiser front axle again because I already have the axle with springs, steering linkage, etc ready. Just need hangers and shackels, then remove and cut off all the old ifs stuff.

Does anyone know if the oil pans are different on a 2wd vs a 1984, 1985 4wd?

 

[meigsrock]

I finaly dropped the tranny the other day. I had to take off the pressure plate to get the thing out. I need to measure the thickness of the clutch friction disc to see how worn it is. I would like to put a new one in but not sure if $ will allow right now.

I put them side by side and there is no way that 4x4 tranny is going in with the stock cross member. I need to find a used 4x4 one or modify a FJ-60 cross member to fit. I also need another set of rear springs so I can beef up the spring pac on it. I did it on my 1992 pickp and it worked well. Of course I wish I could afford new springs, I might look into it Monday also.

I am going to get my extra front landcruiser axle and springs out this weekend and slide it under to see how things will fit up and look. I am also going to get out the IFS rear axle and get that ready to go under the rear.

Going to put in the IFS powersteering and PS box while I am at it.

Any tips appreciated before I dive in.

 

[NorCalBorn]

I finaly dropped the tranny the other day. I had to take off the pressure plate to get the thing out. I need to measure the thickness of the clutch friction disc to see how worn it is. I would like to put a new one in but not sure if $ will allow right now.

I put them side by side and there is no way that 4x4 tranny is going in with the stock cross member. I need to find a used 4x4 one or modify a FJ-60 cross member to fit. I also need another set of rear springs so I can beef up the spring pac on it. I did it on my 1992 pickp and it worked well. Of course I wish I could afford new springs, I might look into it Monday also.

I am going to get my extra front landcruiser axle and springs out this weekend and slide it under to see how things will fit up and look. I am also going to get out the IFS rear axle and get that ready to go under the rear.

Going to put in the IFS powersteering and PS box while I am at it.

Any tips appreciated before I dive in.

Spin the trans crossmember around 180 degrees, or try one out of a 2ndGen 4Runner, 2wd or 4wd since that works for some of the setups and worked for me on my upgrade to 4wd/5-speed.

 

[meigsrock]

Wow what a big project, but progress is being made.
The tranny is out, front IFS suspension is removed, steering box out, driveline out, Oil pan off.

I picked up a 4wd oil pan and oil pickup as well as many other parts like hangers, shackels, etc. from a local shop (green tree fabrication) and they are great. Lots of info, help, and parts.

Just about everyting is torn down. I still need to inspect and or rebuild the axles, and more parts are on order.

The landcruiser front axle is going to be sweet except for the pumpkin size. The down side is it is heavy, and the larger pumpkin will give me a little less ground and oil pan clearance because I am not lifting it mutch, (stock FJ60 springs). But the up side is I own lockers and a limited slip to chose from for the front axle and a set of 4.10 gears for it. Hopfully that is a good ratio otherwhise I will have to buy new gears for both ends.
It is also wider and already set up for cross over steering which is saving me lots of $ so I am using it. WMS on it is 59" and the IFS rear is 58.5" so it is a great match up.

This week I should be able to install my fj-80 master cylinder, cut off the IFS, install the 4x4 oil pan and oil pickup- done, build my front spring hanger, install front spring rear shackels and get the axle located where I want it.

Then I can deal with puting on power steering and getting all of that together, relocated, and put together. If anyone can get me some photos of their powersteering system in their truck I would appreciate it. late 80's and early 90's truck photos wanted. I am not sure how it all goes together, brackets, hoses, pullies, etc. I need to look in my 1992 toyota manual but I am not sure if it is there or not.

The parking break set up is different on my IFS axle so I am not sure how I want to go with this one. I could go line lock, All pro t-case break or mabye fab up the rear drumb breaks to work. I guess I will have to see once the cross member is out and rear axle is swapped. Any suggestions on this one?

It will be nice to have the bigger front and rear breaks. I am Sort of thinking of rear discs while everything is out and apppart. Has anyone tried the Trail gear rear disc kit?

I will post some pictures of the progress soon.

 

[meigsrock]

I got the oil pan and pickup tube put in and when I was under there the lower radiator hose was looking pretty bad so I got some nice heavy duity silicone treated ones from GTF to go in while I still have all the front suspension and steering out and everything is easy to get to.

Local Toyota pro said pulling out the distributor makes it easier to get to the powersteering pump bracket so I went down to napa and picked up new plugs, cap, rotor, oil filter, and air filter too.

I put the FJ-80 master cylinder in yesterday and got a kevlar clutch for it today so I have plenty to keep me bussy this weekend.

Hope the weather holds, driveway project.

 

[meigsrock]

New radiator hoses on
Upper power-steering bracket and pullies on
New fly wheel disc and pressure plate put on

pulled front springs off the fj-60 axle, wire wheeled, and painted them

New air filter put in

 

[meigsrock]

Put my new spark plugs in, cap and rotor on today. New oil filter on but still need to put oil and antifreze in. I may just fill it with water and take it down to have a radiator and heater core flush when I get it back on the road. Hopefully this will keep it from geting hot on hill climbs and make the heater hotter. (budget depending). I picked up a spair blower motor and heater core the other day. The blower motor in the camper is F*&#ing loud and does not blow too hot so hopefully the flush and new motor will help.

Cut out some of the crossmember. I put the tranny and transfercase in and started modifing the landcruiser cross member to fit. (P.S. This did not work! I went with a stock 1985 4x4 cross member, fabed brackets and bolted it in. See later posts).

Also cut out the shifter hole. The transfercase lined up perfect with the old hole and the new tranny shifter is forward. I put the shifters in and they are located good and should work out well.

 

[meigsrock]

pictures of the new hole and mock up.

Still need to figue out how I am going to hook up the spedo. Old one is cable and new tranny has electronic pickup. Any advice on this would be helpful.

 

[Combat Chuck]

just install an electronic speedo into the dash, I don't think there are conversion kits to turn that speedo pickup into a mechanical one.

 

[stevezero]

If you plan on running a GPS unit, they typically have a speedo function. Not as big as the gauge, but its an option.

 

[Hadmatt54]

According to Marlins site your transfer case is a 6B 92-95 pickup & 92-93 4 Runner. A manual speedometer unit from a 6A gear driven transfercase 89-91 pickup 90-91 4Runner or a Type 3 85-88 pickup or 85-89 4 Runner. Just to re-itterate these are all transfer cases from an EFI 4 cylinder.

 

[Hadmatt54]

According to Marlins site your transfer case is a 6B 92-95 pickup & 92-93 4 Runner. A manual speedometer unit from a 6A gear driven transfercase 89-91 pickup 90-91 4Runner or a Type 3 85-88 pickup or 85-89 4 Runner. Just to re-itterate these are all transfer cases from an EFI 4 cylinder.

Forgot to add "should Work" at the end of 85-59 4Runner!

 

[meigsrock]

Combat chuck:
What years electronic spedo are compatable and will bolt into the dash?

Hadmatt54:
So if I find an older t-case spedo unit I should be able to put it in my truck? I will have to look into both these options more.

I have a cable spedo cable unit in the 2wd so I will have to look closer and see if I can install it in my new tranny set up. I would not mind digital, I will have to look closer at both options.


I did find a # on my tranny/t-case. I will clean it off and take note tomarrow.

I wasted about 3 hours tonight cutting more cross member out and trying to modify the landcruiser x-member to fit. I was hoping it would not stick down as much as stock but looks about the same. More trouble than it is worth, and I don't want to waste more down time than I have to.........ya I know too late, but I need it up and running by end of july.

I would love a all-pro member with the parking break on the t-case. Bud-builts are on sale at Trail gear now, but I think I am going to get a used 4x4 cross member for now due to no extra $ right now. I may have to pick one up from a guy I bought fenders and a hood from last week, or GTF may have one.

 

[meigsrock]

I scored big today. I know a pickup guy who works at the car crushing yard so he can cherry pick parts befoer they get crushed . He grabbed some cherry fenders in excelent condition off of a 80's 4-runner for me. I just wish he had grabbed the doors, hood, grille, and blinkers too. It is a shame when good and/or hard to find parts just get crushed. I told him to be on the lookout for good doors so now he knows.

I just picked up a blue hood and set of blue fenders the other day before I got the ones from the friend. The hood is in better shape than mine. So now I have a blue hood to put on and red fenders.

If I sand the brown off back to white it would be red white and blue. haha.

I crawled under the tranny to look at the numbers I found on it. Stamped on the t-case on the bottom just behind the cross member mount is the # 40300000. Not sure if that means anything to anyone.

Have a great 4th of july weekend.