Builds FJ 45 Extended Cab Custom Vehicle Build Finally Begins (1 Viewer)

[D'Animal]

Getting real close.


The Cummins 4BTA/NV4500/Orion4:1HD is assembled.

I installed a new flywheel and a new Luk Clutch assy and a new throw out arm assy.

I tightened the bolts down in 5ft lb increments and snapped 4 of them off when i hit 20ft lbs. I guess I just figured Grade 8 5/16" clutch bolts should be tighter than that.

Nope 17ft lbs is the spec.


I found out that my engine hoist does not want to pick up the assy over 18" from the ground.

 

[orangefj45]

time for the tractor or forklift to take over.......

 

[rockcod]

After hefting the LV onto the trailer, that engine, tranny, t-case combo should no problem for the tractor. Then again, after seeing you lumber jack those big hunks of wood around on your shoulders I am surprised you are using any type of lifting device.

 

[mrqtipp]

sexy...

 

[freds40]

Getting real close.


The Cummins 4BTA/NV4500/Orion4:1HD is assembled.


I found out that my engine hoist does not want to pick up the assy over 18" from the ground.

Sounds to me like you need to lower your rig.

BTW, did ya figure out what part you needed?

 

[D'Animal]

After I got home tonight, I had to modify my engine hoist.

I installed 4" steel casters with bearings and grease jerks instead the little 3" metal casters with a bolt for a center bearing.

 

[D'Animal]

New ones are welded on.


I got all the wheels on and the engine hoist stood back up and it rolled down the driveway.

 

[D'Animal]

I drained the fluids, unhooked everything and pulled the 2F/H42/Split Case assy.

 

[D'Animal]

From starting to drain the fluids to the engine on the ground was under 2 hours.

 

[D'Animal]

I stripped the Cummins down and replace the gaskets and seals.

I also degreased it and painted it Cummins Red.

I picked up the parts to finish assembling it on my way home from work.

Going to be a good weekend.

 

[D'Animal]

After consulting with FC Fabrication, I picked up some 2x4x.188 tubing for new crossmembers and engine mounts.

 

[stash12]

Damn, you're a machine. Rig looks good!

 

[boots4]

I'm sure you've already done the KDP fix. What kind of mounts are you going to use? The engine is looking good.

 

[D'Animal]

What is the KDP fix?

Plan on using new 2F mounts for the front and Dodge tranmisison mount for the rear.

I'm sure you've already done the KDP fix. What kind of mounts are you going to use? The engine is looking good.

 

[boots4]

I cheated and copied this out of my thread but it's good for reference. Hope to see your rig at Rubithon!



This is the KDP, the killer dowel pin. It's located to the left of that bolt head. This thing will work out and you can see what kind of damage it could do with all those gears working together. The pic makes it look like it's close to level with the case but my pin is actually seated well inside the hole which was a good sign.

The fix is very simple. Restrict it from coming out. I had an broken scale laying around that I cut a piece from. I shaped it, bent it, removed all the paint from it, and fastened it with the bolt that was already there. Now if the pin tries to come out it will hit that tab and it will stop it. This is a common problem on the 4bt's and the 6bt's. One of the very few problems needing to be fixed on these engines

 

[1974FJ]

Edit: boots4 beat me to it, more links though....

Kdp ? - Cummins 4BT & Diesel Conversions Forums

Ram Diesel KDP retainer

 

[mrqtipp]

nice Dan kept it up

 

[D'Animal]

I worked on the engine mounting brackets today. I did not want to use the stock front mounts because this assy is so long between attachments points. It would be bolted down on the front of the engine and the AA adaptor behind the NV4500. That leaves about 4 1/2 foot between attachement points with a few things coupling it all together. I read on a different site that the bell housing will crack if supported this way.

I moved my front mounts as close to center of the engine as possible. The rear mount will just "balance" the engine.

It takes awhile when fabing with 3/8" plate steel.

I decided to use the Cradle design instead of the flat design. I am using new 2F engine mounts. if I used the Gell mounts, I would have had to mount them flat.

Here is the exhaust side.

 

[D'Animal]

Enough room for the Turbo oil drain.

All the bolts are not in yet.

 

[D'Animal]

Injector Pump side.


I don't have a starter yet so I took measurements from my tow rig.