4xfletch's Fzj80 resurrection

[4xFletch]

I decided to start a thread on my build and progress. Here's how it all started:
Bought a Land Rover disco 1 to see what it was capable of. I quickly learned that Land Rover are great cars once you replace all of the land rover parts. I went with a Toyota LC suspension and got a 6.2 diesel to put in her.
While doing my daily check on Craigslist for all things Land Cruiser, I found this 96 with a bad engine for a steal. So I bought it. It didn't have factory lockers but I figured I may just part it out or sell it.
The next week while at the pull a part for Disco parts, I find a 96 lx450 with lockers. I quickly leaped into action and pulled them with the harnesses and ecu.
Now in a pickle. Land rover that I have dropped a lot of money into already. But now I have the making's for a dream cruiser. My wife and I debated back and fourth. And while on a short drive in the disco the windows stopped rolling down and starting getting a horrible sound coming from the front end somewhere. This was the sign. Good bye disco!

Here is how I found her: Body in good shape. Interior looked like someone shook up a bottle of coke and sprayed it all over.

 

[4xFletch]

Conversion begins

I have started the conversion to a 6.2 diesel. Using a mark's adapter with 700r4 mated to the stock transfer case. Here is the engine coming out and some insulation I have added to the firewall. Now that I am logging my build I will start taking better pictures and sharing.

 

[4xFletch]

Marks adapter

The adapter kit was very easy to put together. Except one thing: My transfer case shifter did not work with the mount that came with the kit. Apparently later models have a different shifter. Even the folks at Mark's did not know that. I sent them this picture. They say they have never seen my shifter before. Quite strange indeed. So I made my own plate to hold my shifter. Again sorry for the lack of photos. I will be better in the future.

 

[4xFletch]

Shift linkage

I wanted to keep the OEM transmission shifter and try to keep the inside as stock and clean as possible. I bought a Lokar shift linkage (ACA-1800) to connect the toyota shifter to the GM tranny. Easy set up. I had to modify the shifter so the arm is on the opposite side. (Thanks to RTARH20's build thread for the idea.) I had to grind down a little bit of the shifter so It can drop down to another shift position. With no indicator there, I now have a Double top secret low gear.

 

[RockJock82]

The adapter kit was very easy to put together. Except one thing: My transfer case shifter did not work with the mount that came with the kit. Apparently later models have a different shifter. Even the folks at Mark's did not know that. I sent them this picture. They say they have never seen my shifter before. Quite strange indeed. So I made my own plate to hold my shifter. Again sorry for the lack of photos. I will be better in the future.

Yeah the past conversions I have done I just buy a 95 and older tcase shifter. Why go with the 6.2? You get a good deal on it?

 

[4xFletch]

Why 6.2?

I went with a 6.2 because:
1. I want a diesel in my Cruiser
2. I am one of the people who really likes the 6.2. Always have had good expirence with them.
3. Came across a good deal on a recently rebuilt military 6.2. (Which was originally for the Disco before I found Hanna.)

 

[4xFletch]

Update:

Gotta love the random Holidays that give some a three day weekend. Thank you Columbus.

Spent a few hours cutting and grinding out the old motor mounts and install the new motor mounts. I found this mounts that are only suppose for FJ40s and Fj60s. With a little of trimming they work great.

 

[4xFletch]

Motor in!

I got to figure out why my pictures end up upside down. Sorry.:whoops:

Today I got the motor in. This time it went in easy. The first time while putting in to mark out motor mount locations, It was a fight.

Now she's all bolted into place and a very tight fit. Clears everything just wishing I had more room between the exhaust manifolds and the steering shaft.

Since it went in so quickly I started the wiring. Wiring up the diesel was simple enough. I used a Ford starter solenoid to heat the glow plugs and installed a spring load button where the choke knob hole is below the ignition switch. Looks like it is supposed to be there.

Next I have to figure out what wiring to keep from the orginal harness.
Anyone know if I can just plug in the transfer case harness, water temp sensor, and starter wire and just leave the rest coiled up somewhere? Can it be that simple?

 

[4xFletch]

Nothing new

I did not do anything new this evening other than going out and admiring my handy work. Oh and I did stare at my locker diffs and looking forward to when my lift kit comes in so I can put them.

Shameless plug for myself: I have been putting 1FZ engine parts for sale in the classified section for cheap to help fund my build. Which reminds me I'll clean up the extra birfs and axles and sell them too if anyone is interested.

Here's a pic of the front diff laying in wait to be rebuilt and installed.

 

[4xFletch]

Update:

I had to work all weekend so I wasn't able to get much done. I had pulled the driver's side seat to have easier access under the dash. I noticed how nasty the carpets were so I figured I would go ahead and pull all the seats and carpet and pressure wash the carpet. The liquid brown filth that was running out was insane. I washed each section three times. Not all the stains came out but atleast the interior will smell pretty.
I'll be putting a little insulation/ sound deadening material when I put it back together.

More conversion updates soon.

 

[4xFletch]

I have not been very good at updating my thread but I will... and add pictures.
Here is where I am at:
Started the engine this weekend!! She runs but had a small coolant leak. While trying to replace a hose clamp on the radiator I broke off the outlet pipe. Had to order a new rad. At least I'll have piece of mind knowing that it is new. After new radiator is installed its off to the exhaust shop.
Two weeks ago I installed my locker rear end and a 2 inch lift. She's coming together!

Pics soon.

 

[superstan26]

Sounds like it's coming together well. I'm looking forward to pics of this interesting build!

 

[4xFletch]

Updates.

I'm going to try and get caught up on my progress:
I decided to go the electric fan route. I found that the Ford taurus fans pull a lot of air so I decided to use those. I got two out of a low mileage 1998 taurus at the pull a part and built my own shroud. I am using an automatic fan switch with an adjustable temperature setting. I will also be installing a bypass switch where I can override the sensor and turn on both fans in case the sensor fails. I am using a OEM rear heater switch for that. Seemed perfect since it had a little fan on it.

Once I got the shroud mounted to the rad I installed and snapped a pic of how little clearance I have. Was a little nervous about it. I ended up breaking the radiator outlet pipe off so I had to buy a new radiator. While I had it out I trimmed the fans a bit to give a little more room. I have over an inch now.

 

[4xFletch]

Detour

My engine swap is turning into me doing every mod simultaneously. While trying to bleed my brakes I noticed the LSPV was leaking... A lot! I must have damaged it while swapping in the new rear axle.
So now I will be doing the brake proportioner mod.

I guess you got to break a few eggs to make an omelet. Right?

Eventually I will be able to drive her, but that has once again been put off.

Mods I've done so far while in the middle of an engine swap:
E-locker axles complete with ECU, switch and dash lights
Center diff button
7 pin
2 inch lift
hydroboost brakes
Tranny and diff breathers extended
Dual batteries
Electric fans
Rear heater delete
Sound deadening floor board

and having a blast doing it!

 

[4xFletch]

Update:

I thought I would give a quick update. I have been driving the cruiser around on short trips and working out little bugs. The diesel runs great and drives awesome. I have an appointment to get the exhuast started on saturday. After that I will take it on longer trips. Oh and get some bigger tires.

I am loving the diesel cruiser.

 

[4xFletch]

900 lb boat anchor for sale:

So own our way to the exhaust shop yesterday everything was going great. I was up until 12:30 re-wiring the electric fans up and the new set up was working great. While driving: As soon as I see the exhaust shop the engine dies and I coast into a dirt lot about 100 feet from the shop. Engine won't crank. So i popped the hood and discovered oil everywhere but none in the engine. The wife and I run down to the nearest auto part store and I get two gallons of oil. I fill it back up and try again. The engine cranks over for a second and then stops again.

Luckily, there was a tow truck company next door and they towed it to the shop for free. The guy gets it up on the rack so he can look at the exhaust. Meanwhile I was trying to find where the leak came from but there was so much oil everywhere I couldn't tell what was leaking. So I left it there for the guy to do the exhaust which should be done tomorrow afternoon.

Here is where I am now:
1. The engine could be toast. It cranked over once which is giving me hope that it isn't junk. I did some research and found that the chevy oil cooler lines are famous for bursting and destroying engines. Wish I would have read that sooner. But that may not be the problem.
2. I really need to get a lift in my garage that would make life much easier.
3. If it gets done tomorrow, I'm going to tow it home and try and figure out what happened and if I need to look for another engine.

Bummer.

 

[1973Guppie]

good luck with it, you may want to see if it can get towed somewhere to get a good steam cleaning of everything before you bring it back home, that way the truck is clean to work on and find the leak......

 

[4xFletch]

That's a great idea. That would make things more pleasant.

 

[4xFletch]

Quick update: I dropped the oil pan and found metal shavings. Engine is toast. I really enjoyed the 10 miles I drove. Looking at options now. Rebuild or buy a low mileage engine.

 

[half k cruiser]

I went with a 6.2 because:

2. I am one of the people who really likes the 6.2. Always have had good expirence with them.
.)

What's your experience telling you now ? I'm sorry I had to do it. That sucks your motor toasted, especially after all that work and a pretty comprehensive write up to boot. Are you going to put another 6.2 in there ? I would think it would be pretty simple now that you already have everything wired, plumbed, etc.