Dodgy Bro's Rebuilding (fixing) HJ75

[Frosty2086]

Ok so i have begun the task of fixing up my 1989 HJ75 Series Troopy in ernst today! Their is a brief list of items i am intending to do on this machine....

1. Install PTO Winch
2. Rebuild Rear Diff (Completed)
3. Fab up new Bull Bar to Hold PTO Winch
4. Replace Body tub as it is rusted out.
5. Replace extractors as they are stuffed!
6. Clean up engine/GB/Chassis and trace oil leak at rear of engine
7. Convert Air Conditioning Unit into a compressor
8. Camper unit install in rear
9. Raptor line the interior of new tub
10. Overhead consoles front and back
11. Rear diff locker if the budget runs to it
12. More bits and pieces as they appear....

This is my first big 4WD (I have had subarus for a while) and hope to eventually have a portable, reliable home on wheels to support my outdoor activities...climbing, skiing, bushwalking and surfing.

I picked up the car for $2800 unregistered as it was blowing smoke. I replaced the injectors on the side of the road and had it re-registed and drove it home that day Unfortunately i am not made of money, as such everything on the vehicle will be done by myself and my sidekick house mate and GF! No fancy sand blasters here

It has a rebuilt 2H engine and 400k on the clock. The gear box and transfer case are all really tight and nice to drive the engine compression values are spot on factory, so hopefully it will give me a good run! The rear diff was stuffed, and was the first thing to be rebuilt.

The truck as i got her (minus the rack)

The Diff rebuilt. Anything that was rubber was replaced. The unit was wire brushed, sanded, ground and re-painted with POR 15.

Something is missing here! The ring bearing shaft think on the diff centre was...stuffed!

This was supposed to be attached to here....

Getting well over our heads...side panels come off and body is disconnected for the lift...their is ALOT of wires on this thing. But way easier than my GF's corrolla to work on. Lots of room to get to bolts!

Dodgy Bro's doing what they do best. Rigging up a dodgy lift....

Ahhhh the dodgiest Z drag in existence...The oven (aka holden commodore as it loves to cook) gets it done with help from our free hilux ute!

Lifting the body of the chassis with a 1 ton chain block.

Its off....

Chassis in the shed. GB on the group to check the rear main enginer seal and clutch. Spent a good few hours scrubbing the chassis and engine clean of all reachable grease and grime. As bits come off we will be cleaning more of it up.

Extractors off.

Ok so a couple of questions to top it off...

Has anyone run extractors and a PTO winch on a HJ75 troopy. If so how and can you put some pictures up. I am scratching my head on how to do this!

Can you fit a PTO winch from a BJ42 4 speed onto the H55F troopy box. Or do modifications need to be made? Or am i barking up the wrong tree and need to get another PTO box. (I have access to a winch from a BJ42 for free so keen to put this one on!

Ok then...will keep you all informed on how this goes over the next few weeks. Thanks for all the info on this website its great!

Cheers

Frosty

 

[Clint79]

Sounds interesting frosty,
btw your pics don't work

 

[Frosty2086]

Photos

Sorry About the Photos. Will have a look on how to post pictures. In the mean time here is my flickr album if you would like to see some of the pics.

Flickr: Frosty2086's Photostream

Cheers

Frosty

 

[wongtsenhin]

Nice work!

 

[Frosty2086]

Ok attempt 2 at putting up photos. Tried keeping them below 90kb and see how we go.

I removed the old PTO setup of a BJ42 a mate has rusting away in his paddock hoping if would fit onto my 1989 H55F gear box. Unfortunately no it does not.

I then went on the hunt for a second hand one, and their was one for sale locally with 60m of new (ish) cable and a new clevis hook. I picked it up for $450. Spent last night stripping both the boxes apart and rebuilding them with the best bits. I now have a very nice PTO box, i am yet to rebuild the winch.

So question. How do you route the PTO shaft to the winch?

Does anyone have a picture of their setup on a HJ75 Troopy?

Their seems to be two options....

Option 1: Routing the shaft over the top of the extractors and along the top of the chassis rail. This puts the drive sprocket just on the outside of the chassis rail, making it hard to connect the winch.

Option 2: Replace extractors with headers and bring along the inside of the chassis rail. However this seems to run into issues with the steering dampener at the front.

Can anyone shed any light on this?

I have attached some pictures of the over the top chassis rail route i was thinking. I would need to get the new extractors bent out to go around the PTO box as the would currently be touching it.

Thoughts are welcome.

Cheers

Frosty

 

[wongtsenhin]

Go for option 2! Original factory set up is shaft beside the engine. not top of the chassis.

Beside going into this route, the steering damper is not the issue, the shaft will go on top of the steering damper mount bracket.

 

[Frosty2086]

Cheers Wongtsenhin,

Are you running a 2H with headers and a PTO winch? Any chance of a photo or two of the drive shaft routing? The length of two shaft section would be awesome if you happen to know them too!

I have trwo winch's so lots of drive shafts, universals etc. one is out of a BJ42 and one is off a 60 series so will probably have to chop and change the shaft lenghts anyways.

If anyone could shed some light on how to insert images into a post that would be great to. Had a bit of a search and thought i had it with resizing them and then using my flickr link but no luck....

Cheers

Frosty

 

[wongtsenhin]

I'm running a 12HT on my HJ47 and with PTO winch on it. Not on my HZJ75, so can't provide photos. My PTO winch is from 60 series with 2 sections shaft, I did shorten the length of the shaft for my 47.

 

[cicak]

first where you from fill out your details - its also a friendly thing to do we are not an aggressive forum unless you start gloating about HEEPS or other not so unique vehicles - LandRovers etc. However I get away with my Volvo Restore pics here.

ok to post a pic here is what you do.

1. Cut down your pic to 640w by 420 h use microsoft picture manager or similar they easy to drive - it also makes the pics quick to load as they end up 100-190K and not 5MB+ in size.
2. open the reply post thread click on the paper clip (attachments) then click upload (upload means the pics belong to this forum and take up its bandwidth).
3. do the browse thing and select the pics you want I think max 3 at a time. and click upload.
4. Or
5. Put the pics up on your own webpage then clink the Image file the little yellow icon with the mountains
past the whole link e.g. www.geckoadventure.net/BLOG/ga-logo.JPG - like I have done below. I this you can do this with individial FLICKR pics correct.

I have a reasonably toughened BJ75 what pics do you need . And we are about to put a PTO in in not Sure if GOD winch or factory PTO version yet.

posting Youtube pics you can enter this (youtube)x(/youtube)
replacing ( with [ and ) with ] so this demo works and x with from the end of the "=" to the end e.g. from this "http://www.youtube.com/watch?v=ineoQDdqCD4 take ineoQDdqCD4

and you end up with this.



which is my last weekends job riverboarding guide hahaha.

any more posting questions happy to help.

 

[Frosty2086]

Cheers Cicak,

I have updated details...and attempted uploading photos many times. I suspect it is an issue with flickr as i can happily upload your gecko adventures logo.... i will continue to try and work this out.

Anyways bit of track. Anyone got some pictures of the PTO shaft routing?

Cheers

Frosty