Build BJ70-MR Conversion to a PZJ70-MRS

[OGBeno]

Now the main gear cluster:

Chuck your gearset in a vice:

We need to remove and replace the high gear:

And the Low gear:

I’m going the high gear first and then flipping it and doing the low gear:

Remove the c-clip: The Toyota SST is awesome for this specific snap ring:

And then use your puller and pull the transfer hub clutch:

Then use a longer puller to pull the high gear and bearing off in one fell swoop:

Then slide the reduction gear in place and then hammer the bearing home and then hammer the hub back down and install your snap ring. High gear swapped. Lube your shaft!!

 

[OGBeno]

Then flip your gear set and remove the low gear:

Use a longer puller and pull the low gear and bearing in one pull:

Install the low gear:

And the bearing:

And that’s it. Your high-low gear set is complete.

 

[bottombracket]

Preach. This is golden.

 

[OGBeno]

Preach. This is golden.

Just everything I learned from Georg, Marlin, Mudrak, JimC, Robbie, etc. lucky to have awesome teachers.

 

[bottombracket]

It’s a circle and it’s a cycle and everything you give out gets passed on in a new way to a new audience.

 

[bcsteel]

 

[OGBeno]

Continuing transfer case adventures.

Make sure to put your high-low shift shaft in before putting your gear set in..

Your shift lever…. This connects to your shifter in the cab: you line it up on the shaft as you put the rear case housing on.

I painted the location where the thrust washer needs to sit. Mainly so I can see it as I put the rear case housing on. This location moment is critical.

You can double check it by looking in through the PTO opening and see if the thrust washer moves when you engage the gear set:

The gears all meshed and looking mechanically sexy….

Rear case housing installed:

Input shaft nut staked and good to go:

Idler shaft located and love that it won’t come out on the rubicon….

Relative location of the thrust washer to position it correctly.

 

[OGBeno]

High-low detent in place:

This is where your really long bolts go:

Thread lock everything: allows for making sure damn gear oil doesn’t come through:

Finished unit assembly:

In a weird way this seems apropos: using a B series transmission insulator for the cross member to mount a 1HZ transmission.

Hoping to stab it in in the next day or two and then route the exhaust, and more importantly, drop the 5 cylinder boat anchor in and see how it lines up with the B engine.

I have new frame mounts ready to go, but if I can fūck with the extant frame mounts to drop the engine, I’m all about that.

Engine conversions are easy!

 

[OGBeno]

The dumb body guy back in NY decided that bondo-ing the hood captive nut brackets for the hood hinges was a great idea. They broke away almost immediately…. So, had to get rid of the nasty ass bondo and do a quick welding job.

Not the best welding job, but makes it all structurally sound so I can reinstall the hood and not have the hinge mount points break away:

New washer nozzles and holders while I was at it because I “borrowed” the previously newly installed units on a customer’s truck.

 

[OGBeno]

Bell housing installed with new breather boots:

 

[OGBeno]

New clutch fork, clutch fork support ball, boot, throw out bearing. The throwout bearing came with the clutch kit I sourced from Cruiser Outfitters. They package a nice clutch kit for these non-US diesels.

I like to put some anti-seize on the trans bearing support and as well where the pivot ball rides on the fork and where the springs engage with the fork teeth:

 

[OGBeno]

Installed the shifter kit I got from Georg @orangefj45 who I believe designed it with Jason @TRAIL TAILOR .

The only thing missing in this kit (and a part I hope they reproduce) is the shift gate to make sure the shifter doesn’t accidentally shift out of gear.

I’m going to try it first without and see what happens, otherwise, might source one from a 60 series (used) or later 70 series (available new) and modify for my needs.

Everything shifts smoothly. Super stoked how easily this is all coming together.

Also, primed and painted the cross member:

 

[Rigster]

Installed the shifter kit I got from Georg @orangefj45 who I believe designed it with Jason @TRAIL TAILOR .

The only thing missing in this kit (and a part I hope they reproduce) is the shift gate to make sure the shifter doesn’t accidentally shift out of gear.

I’m going to try it first without and see what happens, otherwise, might source one from a 60 series (used) or later 70 series (available new) and modify for my needs.

Everything shifts smoothly. Super stoked how easily this is all coming together.

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Also, primed and painted the cross member:

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This manual shift kit is something that I want to eventually do for my Cruiser. Not because I have had any issues with the vacuum/electric system that is currently on there, but because I like to remove ANY potential points of failure. Not having it working when and where I need it to could cost someone their life.

I may reach out to pick your brain once that time comes since you have already walked this road...

Nice to see your project taking shape and nearing completion! Well done!!

 

[OGBeno]

This manual shift kit is something that I want to eventually do for my Cruiser. Not because I have had any issues with the vacuum/electric system that is currently on there, but because I like to remove ANY potential points of failure. Not having it working when and where I need it to could cost someone their life.

I may reach out to pick your brain once that time comes since you have already walked this road...

Nice to see your project taking shape and nearing completion! Well done!!

Also a part of my calculus.

And thanks! Glad I'm taking some time with a goal to build this thing.

Happy to chat anytime.

 

[OGBeno]

Damn, score! Forgot I had gotten a manual shift gate used from Classic Cruisers!

Boom!

 

[OGBeno]

After 5 years of sitting…

It’s in the air for heart transplant prep!

Some significant deterioration of things after 5 years sitting.

Gonna need new brake rotors, pads, calipers, new drums, some other brake mechanisms.

Front bearing repack, rear bearing repack. New fluids.

Fun.

 

[OGBeno]

Might as well knock out the easy stuff:

Rear bearing repack and cleaning of the rear brake system. All looks good with the rear brakes. New drums and she be golden.

All the hub hardware was rusted to shĩt… fûcking NY. . New hardware and seals on both sides. Koyos look great after a cleaning.

I’ll knock this stuff out tomorrow and then start the cleaning process of the frame and installing new brackets, etc. the critical stuff looks good though.

I’m going to keep the suspension for now and just install new bushings. Going with the parabolic setup later this year.

 

[Tanner H]

Whats the ETA on getting this thing back on the road again? I think you mentioned a Rubicon trip this summer?

 

[OGBeno]

Whats the ETA on getting this thing back on the road again? I think you mentioned a Rubicon trip this summer?

Yeah, I'll be taking the month of June off and going to NorCal for most of it: bike race, then visit friends in Arcata, Ashland, Bend, Quincy, eastern NV, and then Truckee and Rubicon for the TLCA Rubithon event.

 

[coldtaco]

I left the shift gate off on the new transfer/transmission. So far never had it pop out of place.
Do you have a picture of the seal that goes bad to allow fluid to flow from the transmission to the transfer case? Proper orientation of seal?
Love the attention to detail and posting all the part numbers