Cam's FJ60 Gets a Heart Transplant

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fj40charles said:
Make the hose you need so you know the length and orientation of the fittings. Take the hose(s) to an auto parts or anyone else that can make hydraulic hoses and have them made. Should not be too expensive. Keep the original hose you made for a spare.
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Yea...that's what I did, you might want to use a zip tie or something to mark the pump end of the hose or mark one end from the other if like me you have the same style of fitting on each end of the hose. Those hydraulic hoses are fairly stiff and you have to get the orientation of the fittings and the length just right or you will play hell getting it connected. I had two hoses made at the same time...
 
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That's the plan, I'll just make one with the PSC kit and then take that and have it duplicated with crimped fittings.
 
Today I got the old wiring pulled of and test fit the new harness.

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Once I figured out where the first set of injectors went, it pretty much assembled itself. Overall, I'm happy with the harness. A few plugs were a hair shorter than I'd like and the alternator had the wrong plug, but no biggie.

Also, it seems we had a miscommunication about where I was putting the computers and fuse box. I was planning on putting on the drivers fender, as it comes from GM, but the main bundle of wires has been set up to go on the passenger side. It looks long enough to go inside the truck, but I have no idea how I'd get that through the firewall.

This might actually work out better, we'll see. I was thinking I'd have to move my compressor to the driver side to make room for the intake. Now I'll have room on the passenger side for the intake & computers.

The wiring on the engine itself is definitely a lot cleaner and routed better than before.
 
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After a lot of cussing, I got the old fitting off the fuel rail and the new one on.

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Here's the 2F oil sender mounted...

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I realized after mounting the adapters that I left out two o-rings. I also found out that I needed to have installed the shifter bracket before putting on the t-case adapter.

When I went to put the shifter bracket on, I found that I didn't have the correct tail housing bracket. Lokar ships two - one for the 700R4 and one for the 4L60E. I got two 700R4 brackets :clap:

This is as far as that went.

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I'll give Donna a call tomorrow to see if she can send me the right piece.

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Next up, the t-case. I half-assed rebuilt the tcase when I did the h55 swap. I replaced everything except for three bearings.

I still have those, plus a second set of seals and gaskets, so I'll just swap those bearings this time and call it good.

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I got the races to those bearings popped loose with a brass drift, but I'll need to buy a puller to get the roller side off...

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I got this little guy replaced, but not before destroying every flat-head screwdriver I own and finally breaking out the dremel and torch.

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That's as far as I got. Next, I'll swap those last two bearings and clean & paint the case halves before sealing it up.
 
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He's also demonstrating why I would go TBI like Jrob did if I ever do a V8 swap. To each his own but Jrobs swap sure seemed a lot easier.
 
I'm making it look harder than it really is because I don't know what I'm doing and I'm working in third world conditions. I've also only managed to put in half a day's work for the past few weekends, so this could go much faster.

Im not knocking the TBI at all, but in the end, it's the same number of wires to hook up as TBI, plus the same fuel/coolant/power steering/ and exhaust plumbing.
 
Don't bother buying that puller. Go straight to a guy with a BIG press.
 
Cruiserdrew said:
Don't bother buying that puller. Go straight to a guy with a BIG press.
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I did order a two-jaw puller that looks like it would work (if it doesn't break), but I'll look for a guy as well.

I was able to pop the gear off the end, so I was hoping the bearing wasn't any more difficult.
 
wngrog said:
Cam is putting in the detail and using high end stuff. That's all I'm saying. That's why a nice clean install usually costs more in labor than parts.
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#truth
 
Cam-I could use the emission control manual if you don't want....
 
FJ60Cam said:
I did order a two-jaw puller that looks like it would work (if it doesn't break), but I'll look for a guy as well.

I was able to pop the gear off the end, so I was hoping the bearing wasn't any more difficult.
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Well, good luck. I broke a puller on those and gave up. The 50 ton press even had to struggle a bit on my rebuild. If you need to use my pre-load shim set let me know, although I think Beno has a set now too.
 
Cruiserdrew said:
Cam-I could use the emission control manual if you don't want....
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They've both already been claimed.

I've scanned the emissions manual if anyone needs an electronic copy.
 
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Cruiserdrew said:
Well, good luck. I broke a puller on those and gave up. The 50 ton press even had to struggle a bit on my rebuild. If you need to use my pre-load shim set let me know, although I think Beno has a set now too.
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I called my neighborhood garage (Steve's Tire & Auto) this morning to see if they were up for the challenge. I went by at lunch and dropped off the chunk and new bearings. Cross your fingers!
 
Steve's was a bust. Their press wasn't large enough to accept such a large package.

Looks like I will need to venture to the more interesting part of town.
 
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