91 FJ80 Build

[chkn]

So I had been slowly finding components for an LS swap. The 3FE in the cruiser was old and tired. She still ran great but power was lacking and fuel economy was dismal. Two shining points of the 80 series. When driving up long grades the coolant temp would steadily rise and climb. Never overheated the motor but it would probably need to be opened up and repaired in the next few years. The cost to refresh a 3FE is surprisingly high. Might as well put that towards an LS swap...

On a camping trip the alternator died and a replacement wasn't readily available. So the bad alternator was the catalyst to do an LS swap.
FJ Cruiser to the rescue:

On the truck:

Pulling the front apart

Sitting a little light with no powertrain and drivetrain

 

[chkn]

For the swap I wanted a Gen IV so I could go with the 6L80 transmission. I didn't want to mess with AFM/DOD. I didn't feel like paying a premium for a 5.3/6.0 to then spend more money to delete that ticking time bomb. So I searched out a 4.8l. Ended up with a Gen IV 4.8 from a 2008 Tahoe. Then for the transmission I got a 6L80 from a 2010 Camaro ss. Seller said it had low miles and I'm inclined to believe him. Trans fluid looked good and the transmission itself was clean. Bought the Marks 4WD adapter to use the factory transfercase. Oddly enough it was cheaper from Aus than from buying it from Advanced. I guess the exchange rate was in my favor

 

[whiskeytooth]

For the swap I wanted a Gen IV so I could go with the 6L80 transmission. I didn't want to mess with AFM/DOD. I didn't feel like paying a premium for a 5.3/6.0 to then spend more money to delete that ticking time bomb. So I searched out a 4.8l. Ended up with a Gen IV 4.8 from a 2008 Tahoe. Then for the transmission I got a 6L80 from a 2010 Camaro ss. Seller said it had low miles and I'm inclined to believe him. Trans fluid looked good and the transmission itself was clean. Bought the Marks 4WD adapter to use the factory transfercase. Oddly enough it was cheaper from Aus than from buying it from Advanced. I guess the exchange rate was in my favor

Following this. I’m gonna ride out the 3FE til it dies, but I was surprised at the quotes I got for a rebuild vs a swap, I’m always curious why the LS instead of a 2UZ, but I’m not judging, I just prefer Toyota.

 

[chkn]

Following this. I’m gonna ride out the 3FE til it dies, but I was surprised at the quotes I got for a rebuild vs a swap, I’m always curious why the LS instead of a 2UZ, but I’m not judging, I just prefer Toyota.

I looked at a 2UZ. My problem was that I wanted the A750 not the A343. So that somewhat limits the year availability. It's been a minute since I researched but I believe the Landcruiser A750 is specific to Landcruiser so it's not interchangeable with Sequoia/Tundra/4Runner etc. Then I looked at the physical size and the cam in block V8 is physically smaller than the DOHC V8 even in larger displacements. Then I looked at aftermarket support and the LS shines over the 2UZ. So if I ever decide on power adders later its a much simpler process.

 

[chkn]

Now that I had the transmission and adapter I wanted to see how well they fit together. Found a few areas that needed to be massaged with the flap disk but nothing serious. I wish I had more pictures. Hopefully this thread will help me take more photos and document my stuff better.

The rib on top of the transmission needed smoothing so it didn't contact the adapter.

The transfer case adapter contacted the small extension cover so the adapter had to be kissed with the flap disc then it sat perfectly

 

[chkn]

Since I have a 2wd transmission the output shaft needs to be trimmed down to match the length of a 4WD output. I decided why not and 3d printed a cut guide so I could trim it fairly true. Not that it really matters but it was fun to make.

 

[chkn]

Busted out the grinder and got to work on removing the factory engine mounts.

 

[chkn]

Started placing the engine with the engine mounts that came in the Marks kit.

 

[chkn]

Pulled the factory under hood harness out and stripped out some unnecessary wires....

Then started to do the same with the Chevy wiring...

 

[chkn]

Needed some of my sanity back so I moved to the engine and accessories. I believed the engine and accessories would fit without too much issue and I was mostly right. Plenty of clearance for the alternator but not so much room for the power steering.

Measuring the space that I have to work with.

I was having a hard time visualizing it so I transferred that info to onshape and came up with this diagram.

The origin is the crank bolt and the rectangle on the right is the power steering box. The circle is the power steering pump. I placed the steering box using the measurements from the above photos then perused the online catalogs to find which manufactures relocate the power steering to an area that would work with the cruiser. I ended up going with ICT Billet and their OEM alternator and tight power steering bracket. In hind sight I might have been able to save a few dollars and just got a smaller power steering pulley butttttt the factory accessory bracket looks like garbage and now I got +10 hp for looks.

 

[chappysfj40]

good am
this is on irate also. cool beans.

 

[chkn]

good am
this is on irate also. cool beans.

I live a dual life... Mostly on Irate but every now and again hop on Mud.

 

[chkn]

Modified the factory airbox so that it wasn't overly restrictive. Now has a 4" inlet.

 

[chkn]

So we’re mostly up to date. Truck has been torn down in the driveway for almost six months. It’s taking longer than anticipated mostly because I work on it one or two days a week on the weekend in the evenings and my motivation has been lacking

Butttt I sorted out the fuel lines. Put the corvette fuel filter near the stock location. Ended up trimming the factory line and reflaring it so that I could route the fuel line better. It’s in the area of the exhaust so I’ll need to shield the filter or fuel lines.

I need to get more photos of this setup.

 

[chappysfj40]

I live a dual life... Mostly on Irate but every now and again hop on Mud.

me too i just did a cross post
lol

 

[chkn]

Took my first test drive.

 

[chkn]

 

[chkn]

I need to air up the tires to a more road worthy pressure. I think the Autozone power steering pump is dead, because it intermittently works. I need to plumb the crankcase vent on the passenger valve cover to the intake because currently it’s an unmetered air leak that whistles . Need to order fittings to get the AC connected. Also need to adjust the throw of the shift lever because it’s nowhere near where it needs to be. But it was a successful first ride and it didn’t explode so that’s good. Also need to check the trans fluid level just to make sure its good.