Been plugging away at this thing since January. The 5.3 / 4L60e swap has a ton of little details that have to be addressed but people have been doing it for over 20 years so there is a lot of info out there. If you are contemplating it, don't limit yourself to the info just from FJ40s. People have stuffed them in everything you can think of and the information is universal to swaps. Google 'LS Swap' and you'll find what you need.
Here's where I'm at now......
Engine and Tcase mounts in. The original plan was to take it to Valley Hybrids and have them get the motor and trans (5 speed) in with driveshafts. I'd do the rest. I got a text a month before I was to trailer it up to Stockton saying they didn't have room for it and that we'd look at it again sometime this summer, also wait times were 3 to 4 years....... screw that. That was all the motivation I needed to do it myself (and my wife suggested I just do it myself). So thank you Georg for the motivation. I've got to say that it really has been a fun challenge.
I went with the 'propeller mount' on the t-case after trying the FJ60 mount Advance Adapters had suggested. The '60 mount that straddles the frame below the AA adapter would extend about 6" below the frame and be the lowest point of the drivetrain. This option gave me more clearance.
Saginaw power steering conversion is in. I was able to bend the stock Suburban power steering pressure line that was still on the 5.3 to work. That surprised the hell out of me actually. The original line was bent up to look like a pretzel. I'm not running a cooler on it just yet; it won't be turning anything bigger than 33's.
Hooker manifolds that dump between the 3 and 4 hole and inside the frame were a good option. Options are limited where I live so this was a good fit. Still waiting on manifold gaskets to get them on.
I've never liked the stock fuel tank inside the passenger compartment. I had a seem split on the original tank that I repaired about 15 years ago but never really trusted. So I installed a Downey tank I bought from Mark. I installed a submerged LS Swap fuel pump from Speedway Engineering and the fuel level indicator from Dakota Digital. Still waiting on some AN6 fittings that will fit under the tub. I'll run a single line up to the engine, the filter / regulator in the top right of the picture has a return line that circulates back to the tank.
Next up is driveshafts and an exhaust system then the tub will go back on and I can start on the wiring.
The sensors that are needed for the LS swap include the VSS sensor and a second circuit from the brake light switch for the torque converter. The VSS is housed in the AA coupling between the 4L60e and the T-case and the brake switch is from BP Automotive. I ended up using their stand alone gen III harness that will get installed once the tub is on.