6/'72 FJ55: stock drivetrain swap to '84 FJ60 drivetrain (1 Viewer)

[threadchaser]

Dirty FJ60 carb

Post vacuuming, pre-shower. Tomorrow I'll see what that can of carb cleaner is capable of.

I don't know what I'm doing but washing it down cannot hurt, is the thought. I'm hoping to get lucky and just bolt it on in order to postpone opening it up, breaking it down, and giving it a proper bath in Berryman Chem-dip or such.

After the shower, in the background is a bottle of Super-Lube. I'm thinking to finish with some teflon perfume, on the outside only, while manually exercising all the linkage.
http://www.super-lube.com/drifilm-aerosol-ezp-69.html

 

[threadchaser]

Seems SOR's aftermarket(?) carb-insulator-with-integrated-heat-shied does not have the two gaskets bonded to it. Toyota's has bonded onto the insulator two matching gaskets top and bottom i.e. each gasket has one big hole for each of the two barrels.

SOR instead, on the bottom, is providing a separate gasket with only one big "oval" hole shared by both barrels i.e. the plenum gasket as used in 9/69-12/74 before the whole questionable carb-insulator-with-integrated-heat-shied-and-two-bonded-gaskets thing came into play. (Doesn't seem very Land Cruiser-esque to me.)

While pulling this insulator-and-heatshied from the donor FJ60 I hosed my bottom bonded gasket. I think I like where SOR is going with this. So scrape off the broken gasket and use a plenum gasket is the plan.

See http://www.sor.com/cat042.sor for pictures on the tab labeled "Gaskets and Rebuild Kits."

SOR's 042-90B 2bbl Base Gasket- Fits 3/69-8/87 2BBL Carb

SOR's 042-91 2bbl Plenum Gasket- Fits 3/69-8/87 2BBL Carb-Toyota does not offer this gasket separately, it comes with the insulator

 

[threadchaser]

Cleaner FJ60 carb

3 spray cans of carb cleaner later. I ran out. 2 more should finish the job tomorrow. This was all external spray and scrub with a toothbrush.

This carb is much happier already. The linkage is much freer and both butterflies rotate easily which was very much not the case this morning. The idle adjustment screws look virgin. This carb may never have been screwed with.

I'm trying to get away without tearing down the carb but I wonder if removing the plugs to the jets in the bowl (right below the sight glass) and spraying some in there would be too clever by half...

 

[threadchaser]

For connecting the FJ60 2F carb to the FJ55 body, the plan is to stick with the body's stock cable'd accelerator pedal and convert the carb to work with a throttle cable, a change from the mechanical linkage that is stock on FJ60s.

If Toyota abandoned the cable for the mechanical linkage there is probably a good reason for that but I do not know it. Converting the body to mechanical (different accelerator pedal, some minor body cutting and welding to accommodate the FJ60 pedal, bits to hang the mechanical linkage off, and linkage that fits the FJ55) seems like a lot more work though compared to bolting on two little bit in order to convert to cable.

Yesterday I ordered a Trollhole kit for doing the mechanical to cable conversion. Trollhole has all this worked out as he sells his carbs set up for either cable or mechanical linkage. I'll write it up when it arrives. Seems it includes a bracket on the carb to hold the cable end, a Lokar S-1034 to adapt the throttle to the cable, and one or two other bits including what sounds like an elegant solution for mounting a return spring. I also need to get a new cable as the one I have was hacked such that there is not adjustment hardware on the carb end of the cable (Trollhole says: "spector or fjparts").

P.S. Somewhat related, I found this while trying to piece it all together. I don't need it (I don't have a bellcrank on my 2F carb) but for the record:
http://www.marksoffroad.net/1specials/1specials.html
057-11 Accelerator Cable Mounting Bracket, reproduction. Essential but often missing piece on the 1970-1972 carbs to tension the accelerator cable to the bellcrank. Got tired of hunting for strays and paid to have these reproductions made.

 

[threadchaser]

Dang it! Chatting with JimC leads me to believe that I'm currently working on a sub-optimal solution for the throttle linkage. So, this will probably end out with me getting a bellcrank to add on to the carb from him and throttle cabling to that. But the solution he advises and which mirrors the evolution that Toyota went through is to go with mechanical linkage.

I don't have enough power nor gear here to do quality welding which is required to get a mechanical linkage accelerator pedal onto this pig's body. I have a '78 pig at my home base (500 miles away from me at this time), which I assume has mechanical throttle linkage. So, I'll mimic that when it's in front of me.

In the meantime, expect two cable based throttle linkage paths the be explored over the next week or so, which should be sufficient to get this pig moving (well, in terms of throttle linkage; lots of other issues still to go before this things moves). And mechanical linkage will happen down the road a ways.

 

[threadchaser]

Fuel return line

Another gift from the giving truck: a fuel return line. This came off the donor FJ60. Thanks for the clue-in JimC.

Seems that Toyota changed the fuel pump in 1/79. Before that there were only two ports on the fuel pump: one line from the tank and a second went up to the carb. I'm not clear on this but it sounds like there were fuel return lines on some of the carbs before 1/79, again not sure. Then with the later fuel pump the third fuel fitting appeared on the fuel pump and that one is the fuel return line.

This 6/72 FJ55 does not have a fuel return hard line (nor fuel hose) and I hear the stock gas tank didn't have a port for fuel return. This truck does not have the stock fuel tank, rather it has an aftermarket 30 gallon tank which came with a port for a fuel return line, which seemingly was simply plugged:
https://forum.ih8mud.com/fj55-iron-...rivetrain-swap-84-fj60-drivetrain-13.html#242

Currently, a 2F with a 3 port fuel pump is going in the truck and there is a fuel tank ready for a return line. So, a hard line connecting the two would come in handy. JimC pointed out that something fitting that description was to be found under an FJ60.

In these pictures it's just zip tied to the body. Note the donor actually gave two lines which are paired together via some clips; I will only be using one of the two. After the engine and other parts are installed I'll permanently affix it. Kinked up from the factory to follow the frame rail closely the FJ60 fuel line none the less fits very well in the FJ55 with the ends very close to where the stock fuel hard line routes to.

There is a very brittle, bend in half, cracked fuel hose in the third picture. Given its condition, all fuel hose in the vehicle will be replaced. The well lettered small bracket on the left is where the stock fuel filter was, it seems:
https://forum.ih8mud.com/attachment.php?attachmentid=875133&stc=1&d=1394729638

 

[threadchaser]

Carb insulator and bonded gasket materials versus naphtha. Let's see where this goes over the next 24 hours.

[EDIT: a day later, nothing. The naphtha didn't touch the insulator, it's bonded gasket, nor the bonding material. At least that demonstrated that naphtha is a safe cleaner for the insulator-cum-heat-shield. Still trying to figure out how to safely separate the broken gasket from the insulator.]

 

[threadchaser]

SOR manifold gaskets

In this picture are 3 manifolds gaskets: 2 identical 2F gaskets and 1 F gasket, which is stacked atop one of the 2F gaskets.

http://www.sor.com/cat044.sor?tabpage=TAB5
F: 044-01B Manifold Gasket - Fits 1968-1974
2F: 044-01C Manifold Gasket - Fits 1/75-8/87
Not clear to me if these are OEM.

Consensus seems to be that the gasket to use is OEM or Felpro, which might even be the same thing.

Mixed reviews on the newish Remflex technology. Mark W says avoid the SOR Kevlar:
https://forum.ih8mud.com/showpost.php?p=1657425&postcount=17

For the 2F: "OEM Part number: 17172-61020 / 17172-61030 / 17172-61031 / 17172-61040 / 17172-61041"
http://www.fjparts.com/75-87-land-cruiser-fj40-55-60-manifold-gasket-p-1708.html

Big take away message seems to be that manifold bolts should be repeatedly retorque during the first weeks after install or at least retorque after about 10 heat cycles, engine does not need to be warm:
https://forum.ih8mud.com/showpost.php?p=1671912&postcount=26

Some people seem to like to double up the gasket in order to help prevent leaks.
https://forum.ih8mud.com/60-series-wagons/125958-double-manifold-gaskets.html
https://forum.ih8mud.com/showpost.php?p=2905657&postcount=36
"i double up the felpro gasket party w/ some aerosol spray copper coat. i've tried several combos but this seems the seal the header the best."

 

[threadchaser]

Here's more bits I pulled from the donor FJ60. I should have pulled these when I pulled the carb and emissions bits:
https://forum.ih8mud.com/fj55-iron-...rivetrain-swap-84-fj60-drivetrain-18.html#352

The green plug is for the carbs idle cut solenoid.

The dirty cap with yellow wire is the weather cap for the oil pressure sender unit.

The doodad with 3 hoses coming off it is the "gas filter" which is to be found on the front top of the intake manifold, useful if someone removed it while putting on a Weber and the truck is now being de-Webbered back to the stock Aisan (not to be confused with "Aisin" or "asian") carb.

So, consider adding these to your shopping list next time you're raiding a donor truck.

 

[FJ40Jim]

Also grab:
-The plug that goes into the FJ60 alternator. Very useful if upgrading any earlier Cruiser to the internal regulated 79-87 alternator.
-The plugs that go to the ignitor (power in and tach out).

 

[threadchaser]

Also grab:
-The plug that goes into the FJ60 alternator. Very useful if upgrading any earlier Cruiser to the internal regulated 79-87 alternator.
-The plugs that go to the ignitor (power in and tach out).

Will do tomorrow. Thanks.

 

[PabloCruise]

What exactly does that gas filter do?

 

[threadchaser]

What exactly does that gas filter do?

All I know is that I need an intake manifold vacuum tap.

But since there's an air/fuel mixture in the intake I guess it also acts to filter gas from backing up into the vacuum hoses, perhaps without it there could be an unsafe pooling of gasoline in some circumstances? Just a guess though.

 

[FJ40Jim]

It's a filter for gas (air). Not a filter for gasoline. It is just a vacuum fitting to connect 1,2 or 3 vac hoses to manifold vacuum. It is called a gas filter because crimped inside is a wad of gauze, so that if the Cruiser is crossing the desert and a vac hose comes off the fitting, sand will not be sucked into the engine through the vacuum leak.

 

[PabloCruise]

Any updates here?

I enjoy your detailed approach to this project. Hope to see how things are going with this!

 

[PabloCruise]

All I know is that I need an intake manifold vacuum tap.

But since there's an air/fuel mixture in the intake I guess it also acts to filter gas from backing up into the vacuum hoses, perhaps without it there could be an unsafe pooling of gasoline in some circumstances? Just a guess though.

Any progress on this? I really enjoy reading about your Pig and your approach!

 

[jerseypiggy]

Bigsal... I have an FJ55 and just blew at least a piston ring on a 350 SBC. I am planning to drop in a rebuilt or crate 350 but want to take this opportunity (?) to swap/upgrade from the stock 3-speed tranny.

I am thinking either 4-speed H42f or 5-speed Toyota H55F....or possibly go with a NV4500 for GM. I'd really prefer 5 speed if its not a huge additional hassle/expense to install....would like to get this rig on a highway someday.

I want to minimize need for adaptors and whatnot (although prior owner already put in V8-3speed adaptors and the crossmember support for the old tranny)...and I want to keep it relatively simple cuz I am finding it hard to find a guy to do the work (I cant do it).

Thoughts on best tranny to mate to the V8 ?

 

[PabloCruise]

I hope @threadchaser comes back some day to tell us about this...

 

[PabloCruise]

I hope @threadchaser comes back some day to tell us about this...

I don't think he is coming back...