78 fj40 , 1kz-te , h55f , orion

This site may earn a commission from merchant affiliate
links, including eBay, Amazon, Skimlinks, and others.

Thanks for the compliment ! I have almost 30,000 miles on it now , and it is still my daily driver , except when it rains . My 40 is rust free and the last one I had rusted out . I want to keep this one rust free .I have a Chevy Blazer that I have been doing a frame off restoration on all winter , so the fj40 is the only vehicle I have running now . The 1kzt doesn't have enough power to tow anything , but it has more power than the 2f engine had and nearly double the gas mileage , but I didn't have 5 speed on the 2f . I never got around to posting photos of the custom radiator I made , but it really cleaned everything up and always runs cool ever since I installed it . There is more to the orion to H55 than an adapter plate . You have to find a hub that fits the output shaft splines of the h55 , bore out the center of the orion input gear and weld splines into it as in the photo I posted . I don't understand why orion doesnt offer an h55 kit . They could sell so many more kits if they did . The orion really is an incredibly strong transfer case . I love it , it has worked perfectly .

I love the Orion too. It’s the main reason I haven’t tried going the H55 route. Looks like I’ll have to go nv4500 if I want to keep it and get a 5speed. Might have a 12 inch rear driveshaft hahah. I guess if you got a shorter motor in there you could push it all forward.
 
I love the Orion too. It’s the main reason I haven’t tried going the H55 route. Looks like I’ll have to go nv4500 if I want to keep it and get a 5speed. Might have a 12 inch rear driveshaft hahah. I guess if you got a shorter motor in there you could push it all forward.

Why not just run a split case with 4:1 gears and keep your life simple? Not than there is anything wrong with NV4500s, but no fancy adapters required if you keep it all Toyota, it'll all just bolt in.
 
I think the 4:1 gears for split cases have high range reduction, and I’m already on 4.88 gears in the diffs
Yes , putting in the shorter 4 cylinder diesel allowed me to move the engine forward enough to fit the longer h55 + adapter and keep the origional drive shafts and parking brake .
 
I have had it out on a 96 deg. day and it runs cool now . It will go up steep hills at 65 mph in 5th gear without getting hot . EGt's rarely get over 1000 F going up a steep hill . I have been wheeling on a hot day and it stayed cool . I have been getting between 22 and 26 miles per gallon mixed driving . It really runs great , and sounds great . It has been my daily driver . Has not used any oil at all . It does vibrate at idle , but not too harsh . I know I don't have the right motor mount set up for this engine . I also wonder if the stock dual mass flywheel would make a difference in idle ? Just above idle and higher , it is real smooth and quiet .

View attachment 775348

View attachment 775349

View attachment 775350
First, I want to say that I am VERY impressed by your build. I think this thread is amazing and I could not stop reading it. Thank you for sharing and posting.

Being a complete novice at swapping engines, I am still looking to move forward with a 1KZ-T or TE swap. The only piece that makes me nervous is the fabrication of the motor mounts. Can you share a bit on how they were designed. I see that they are weldments and I assume you used mild steel.
 
First, I want to say that I am VERY impressed by your build. I think this thread is amazing and I could not stop reading it. Thank you for sharing and posting.

Being a complete novice at swapping engines, I am still looking to move forward with a 1KZ-T or TE swap. The only piece that makes me nervous is the fabrication of the motor mounts. Can you share a bit on how they were designed. I see that they are weldments and I assume you used mild steel.
I marked and measured the original transmission and engine location before removing it . You want to be sure that the center line of the of the rear output shaft on the transfer case is exactly where it was in all 3 directions when you put the new engine / trans in . You also need to know exactly where the centerline of the crankshaft is [harmonic balancer] and put the front of the new engine on that centerline . The alignment and angle to the floor of engine/ trans is very important . Basically the crankshaft center line needs to be parallel with the frame center line . I have seen many engine swaps where the engine is not parallel and this is a bad idea [ it needs to be closer to the drivers side of the frame but parallel , this makes room for the front driveshaft ] and engine level side to side . The output flange on the transfer case needs to be exactly the same height , in the same location front to back and side to side , and at the same angle to the floor as it was before [ the engine /trans center line will be angled up towards the front of the engine ]. On an FJ40 the center of the cone shaped stamped steel cover on the back of the transfer case is the same centerline as the crankshaft . It can help with alignment . Take as many measurements as you can and write them down . I also put a lot of marks on the chassis and frame to measure from and align to . Then I used floor jacks , bottle jacks and cherry picker to place the engine on center line , leveled the engine side to side off the front of the cylinder head with the lifter cover removed . I welded mild steel plates to the frame to strengthen it before fabing motor mounts . I used FJ40 motor and transmission rubber mounts . I used the old ones to fab it all up then replaced with new . That was so long ago I don't remember how I did it all , but it was simple to figure out . There might be more photos of the mounts in the video , I'm not sure but the video has all the photos I took in it . And Thanks for the compliment ! Good luck , engine swaps are fun.
 
Beerfart, that’s an amazing 40 series! Your fabrication skills are insane, very, very inspiring.

There‘s a recent series on making good power with these engines from YouTube user TRAV30387. It’s not cheep, but looks real fun!

I plan on swapping a 1kz into my mini truck when I geat tired of living life in the slow lane. I still need to accumulate all the critical pieces, like a shop, first though!
 
Youtube Video link of Canyonlands, The Needles, Elephant Hill trail 1KZT FJ40, Canyonlands

tempImageE10usd.webp
 
Back
Top Bottom