80 Series H151F 5 Speed Manual Transmission Swap - Includes RHD HDJ81 & LHD FZJ80 (1 Viewer)
- Thread starter gnarlynick2072
- Start date
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After swapping the brake pedal, I moved onto installing the clutch master cylinder and clutch pedal. I purchased the master cylinder using the p/n provided by Nick however all the clutch pedal components came from Yan at Cruiser Addiction. The benefit: All the parts are brand new, OEM Toyota. The not so great: It took over 2 months to receive the parts and the price was $300. The end result was a totally factory clutch assembly which bolted in with little effort. Here are the components prior to install.
The LHD clutch pedal and master cylinder install was a bit different from the RHD stuff. My USA model had a large rubber grommet on the firewall (and a pre-existing hole) where the master cylinder needed to mount however there were no actual mounting holes. On the footwell side, there was plenty of room to fit the pedal and I didn't have to move anything around. Also, it turned out that my truck had an existing threaded capture nut already in place so I didn't have to drill a hole through the cowling like Nick did. Like the hole in the firewall, the capture nut was in place but not in use by anything. Having it saved a lot of time.
One of the bigger hassles with this was the fact that there were two threaded studs on the firewall extending into the footwell area. They had to be removed in order to fit the pedal bracket and master cylinder in place.
One of the bigger hassles with this was the fact that there were two threaded studs on the firewall extending into the footwell area. They had to be removed in order to fit the pedal bracket and master cylinder in place.
- Thread starter
- #106
Also, @Rock40 what year 80 do you have? Would be good to know which versions and years have the capture nut for the upper clutch pedal bracket. Maybe I'll make a list here with versions which reported to have/not have the capture nut. @FloridaFJ80 Frank, did yours have the capture nut for the clutch pedal?
That'd be nice for other guys who want to do this but it was pretty obvious he tore off the P/N's from the pedal and bracket on purpose. I found all the other small parts, just not those two.
- Thread starter
- #109
I added a photo of the clutch bracket above to give folks an idea of what it looks like. The hole for the bolt which goes into the capture nut is in the upper right of the photo.
The threaded studs on the firewall were spot welded onto the firewall and I elected to drill them out/off and just plug the holes in the firewall afterward. That ended up working well but you'll need an angle drill to get at them from the firewall side. You could also zip them off with a small dremel but I didn't want all the dust and sparks inside the cab.
Nick did a great job of writing up how to line up and mark the holes for the master cylinder. It helps to have an extra set of hands because you only have one chance to get the master cylinder on straight.
The threaded studs on the firewall were spot welded onto the firewall and I elected to drill them out/off and just plug the holes in the firewall afterward. That ended up working well but you'll need an angle drill to get at them from the firewall side. You could also zip them off with a small dremel but I didn't want all the dust and sparks inside the cab.
Nick did a great job of writing up how to line up and mark the holes for the master cylinder. It helps to have an extra set of hands because you only have one chance to get the master cylinder on straight.
I assembled the clutch pedal assembly (which is totally goofy to the say the least) before I installed the bracket or anything in the vehicle.
I had no instructions and many, many small pieces. I utilized an online diagram and my wife and I spent about an hour piecing it together. When finished, I was sure that we didn't have it right. To anyone else doing this: The action/force of the pedal assembly seems TOTALLY BACKWARD AND WRONG. There's a large goofball cam which levers back and forth under the dash and the pedal assembly DOES NOT spring back to the outward (released) position like I expected.
After much frustration, I got in touch with Nick and he assured me that the assembly was correct. He added he had similar concerns/issues however the pedal worked correctly after the clutch master/slave cylinder were installed, bled and the master cylinder pushrod was adjusted correctly.
Here's a pic of the whole mess
I had no instructions and many, many small pieces. I utilized an online diagram and my wife and I spent about an hour piecing it together. When finished, I was sure that we didn't have it right. To anyone else doing this: The action/force of the pedal assembly seems TOTALLY BACKWARD AND WRONG. There's a large goofball cam which levers back and forth under the dash and the pedal assembly DOES NOT spring back to the outward (released) position like I expected.
After much frustration, I got in touch with Nick and he assured me that the assembly was correct. He added he had similar concerns/issues however the pedal worked correctly after the clutch master/slave cylinder were installed, bled and the master cylinder pushrod was adjusted correctly.
Here's a pic of the whole mess
It's a 96' USA model 80. Originally with a gas engine and auto tranny.
As the clutch pedal is depressed, the big white cam goes flipping up under the dash. I've never seen anything like it. I got lucky and only had to zip tie a piece of the wiring loom back away from the cam. Other than that, it fit just fine.
Installed!
Installed!
- Thread starter
- #116
CLEAN install! And nice clean interior!
Funny that on LHD trucks, the clutch pedal is so close to the brake pedal. On RHD it's farther away.
Here's a shot I took of the pedal setup on an early model LHD. I took these pics on a 91 80 series LHD in the middle east. This backs up Ross's install.
Like his setup, pedals are close together:
Funny that on LHD trucks, the clutch pedal is so close to the brake pedal. On RHD it's farther away.
Here's a shot I took of the pedal setup on an early model LHD. I took these pics on a 91 80 series LHD in the middle east. This backs up Ross's install.
Like his setup, pedals are close together:
Yeah, the pedals are spaced very similar to my 84' Toyota Mini-truck.
Tapage
Club 4X4 Panamá
you guys have the part number ( yeah .. bit lazy to look for in on the EPC ) for that spring between pedal and bracket .. ( helping the pedal push motion )
- Thread starter
- #119
You should also get the prices together. So we know what we paid in total for parts.
