FJ40 --> Isuzu 4.9 (Automatic Conversion)

[mudmud]

Hi all!
I'm the owner of an FJ40, bought for my wife, I know I keep saying my FJ but it's really hers but I like it too!

After the fact I find out..... she HATES manual trannies...
After a lesson or two she asked can this be converted to automatic...
Well, being a man and litteral I said "Yes its possible...."
She said, "well do it...."

So here I have been looking around for tips on converting my FJ40 to Automatic when I realized that since everything has to come out anyway.... I could do that AND give it something with a few more mpgs and would last for ever as opposed to going with a small block Chevy that would suck.... (hey I got 1, fun and fast but I can watch the gauge move!!)

January will be the start of something fun!

So I have a 1976 FJ40 that I bought from a forum member (hi Jeff!)
He had done a great frame off restoration.
I live in Chugiak Alaksa which is a small community just north of Anchorage Alaksa!
I am planning on buying a 4BD1T Isuzu 3.9 in January and using a conversion kit from isuzudieselswapper.com (carcrafter22@yahoo.com) I don't really know if there is a company name but I like their info on the web.
I plan on mating it to a 700R4 or 4L60 depending on availiblity and and other info I may find between now and then...

Saginaw power steering, and I need to talk to Advanced Adapters about the transfercase and of course all the other mounts which I may or may not fab myself....

This sound like a fun project and I would like to be finsihed with it by spring, which comes about June 1st in my area...

I work on the North Slope of Alaska, (Prudhoe Bay) for two weeks then am off two weeks, so my build will follow that schedule, most likely while I'm working on my build there will be no info, then when I'm up at work I'll post pictures and results... we'll see how that goes!

Here is a picture of the FJ40 with my wife in it pretending to drive....
When I get photobucket or something I'll do the whole upload from web... I'll get it figured out yet!!

I do want to thank all the people in the thread: https://forum.ih8mud.com/diesel-tech-24-volts-systems/128585-isuzu-4bd1t-swap.html

Whew! What a read that was, it took me 3 days!!! Full of great info and people!!
Specific inspriation is from Georg (orangefj45), Dre (dieselcrusierhead), Clay (Rhino), and others really inspired me to do this, so even tho I've never met or even talked to these guys it's like I know them... but I don't... lol

Carl

 

[Nexxussian]

That should make a nice swap, you will have to remember to give it back to her when you finish the swap though.

If you haven't already, make sure to email Randy (Carcrafter22) at Isuzu Diesel Swapper, he is knowledgeable, and helpful.

He has several threads over on 4BT swaps, same username.

What trans were you thinking of?

 

[D'Animal]

That sound like a nice combination.

I am storing Mr. Fletchers FJ 55 with a similar combination so if you need any pictures of the Isuzu, 700R combination just let me know.

 

[mudmud]

@Nexxussian:
I plan on mating it to a 700R4 or 4L60 depending on availiblity and and other info I may find between now and then... and I do have that link, having Randy at Isuzu Diesel Swappers is one of the reasons I decided this was a valid way to go!
Yeah, I'll have to "let her go", but my wife and I are pretty fluid in our cars (we have 7)! So we'll both get to "play"!!!

@ D'Animal:
That would be great... I was leaning towards teh 700R4 as it seems good for the conversion, pics would be great! I'm gathering up all availible data during this ramp up period, I don't get home until the 10th of Jan and then that time home will be more about getting my garage ready, cleaned out and a floor treatment so that it looks professional and I can easily clean the floor.

The FJ is outside right now and so I'll be bringing it in from zero degs to garage temp.... and if I'm lucky I'll have the body off before I go back to work on the 26th! Gotta start buying some parts and pieces as well!

Thanks for stopping by!!

 

[Combat Chuck]

I definitely advise reading up on Astr's build:
https://forum.ih8mud.com/diesel-tech-24-volts-systems/268941-isuzu-4he1tc-into-fj62.html
It's got alot of good info, and also passes along the knowledge that the Isuzu transmission is made by Aisin, and the FJ62 auto and the Isuzu's auto can play musical tailhousings, which means that there is an adapter-free transmission option for you that will cost less in the long run, and eliminate potential weak links and driveline length issues inherent with adapters. Furthermore, running the transmission that truck's meant to have will eliminate obscure aftermarket parts that may be unobtanium in the field.

Good luck!

 

[mudmud]

@Combat Chuck:
Wow, I did not know that the Aisin tranny was that flexible... I need to read up on that, seemed at one point that there was a hitch... like no overdrive or something... but I should stop my ramblings until I do my research...
Maybe it was the length of the tail housing /// considering how short the FJ40 is maybe that's why I discounted it... whelp, guess I'd better get reading!

 

[mudmud]

I just got thru the 1st page of Astr's build and it's an amazing start! Can't wait to get thru the next 11 pages...

 

[Nexxussian]

Yes, that's an amazing thread, and a stronger trans than the 700R.

If you decide to go the adapter route, instead of the hybrid trans route, I expect Randy will reccomend against any 700R variant, as he hasn't had good luck with them.

He also has a Ferd pattern adapter in the works (one or two prototypes in testing now, as I understand it).

That would allow the 5R110 and whatever T case that comes with.

I hope that's more help than hindrance.

 

[astr]

Exactly which Isuzu engine are you contemplating? The 4BD1/2 are 3.9 liters and the 4HE1 is 4.8 liter. The next Isuzu engine commonly found in the US is the 4HK1 at 5.2 liters. Both the 4HE1 and 4HK1 share the same transmission end bolt pattern and are commonly fitted with the Aisin AW450 automatic transmission. The 4H series are totally incompatible transmission-wise with the 4B series which to the best of my knowledge never were mated to an Aisin transmission. They typically came with the Jatco JR403 automatic, which, though very similar is spec to the Aisin, does not have the best reputation and won't accept the LC T-case.

I do remember somewhere here Isuzu 4BD1T/2T someone (I think it was Bobpr) mentioned that there may be a version of the JR403 that came with a T-case.

 

[Combat Chuck]

Exactly which Isuzu engine are you contemplating? The 4BD1/2 are 3.9 liters and the 4HE1 is 4.8 liter. The next Isuzu engine commonly found in the US is the 4HK1 at 5.2 liters. Both the 4HE1 and 4HK1 share the same transmission end bolt pattern and are commonly fitted with the Aisin AW450 automatic transmission. The 4H series are totally incompatible transmission-wise with the 4B series which to the best of my knowledge never were mated to an Aisin transmission. They typically came with the Jatco JR403 automatic, which, though very similar is spec to the Aisin, does not have the best reputation and won't accept the LC T-case.

I do remember somewhere here Isuzu 4BD1T/2T someone (I think it was Bobpr) mentioned that there may be a version of the JR403 that came with a T-case.

Glad to have you contribute, Astr, I realized I was somewhat misleading with my info there. I think it's been about a year since I last read your thread.

As Nexxusian said, there will be some anit-700R4 sentiments, and I would gladly captain THAT bandwagon, but I've never heard either entirely positive, or entirely negative feedback on the 700, either people love it, or they hate it. Maybe the Ferd option is a better one, though I recall hearing that their Torque Converters are a bad joke, though they make a bulletproof valvetrain and their gearsets are stout. If you can fine a complete 4HE1, that would be my honest recommendation, it's a smidge bigger, but has a deal more refinement, and as I've read, stronger head.
My only experience is with my neighbor's NPR which is a 4HE, and that thing's got some power!

Whatever the case, in a SWB 40, no matter what transmission you get, you'll end up with a drive-shaft about the length of a ham sammich.

 

[mudmud]

@Astr: Thanks for visiting!

Well I do really like the 4BD1T as it is indirect inj, w/Turbo, plus I had heard but not confirmed that TH350 tranny would mate up and be the shortest, which for the FJ40 is part of the consideration..... but no over drive... but then also heard that the 700R4 or 4L60 were strong enough for a diesel.... and has over drive!!

So to answer your question, I like the 4BD1T. But after reading your experience, I do like the 4H series but wonder if it’s a bit overkill in an FJ40??? The 4BD1T is 700lbs is yours about the same weight? Also what is the overall length of your drive train....??
This vehicle will be used primarily for my wife to drive back and forth to work 20 miles and for her to do a little mudding.... I was thinking that the 700R4 would be ok... I like that is and the 4L60 have over drive... and like that the TH350 is short...
In a nut shell: I want a engine/tranny/transf that will cobble together farily easy. If I have to use adapters I will but would like not!!

I'd appreciate all feedback on this.

@Combat Chuck: Yeah, I am concerned about the ham sandwich drive.... lol

Thanks for showing up guys, as you can see I do need the feed back to help me before I end up buying stuff and regretting it....

later,

 

[astr]

...Also what is the overall length of your drive train....

65" from fan mounting flange to back surface of rear output flange.

...Well I do really like the 4BD1T as it is indirect in...

The 4BD2 is indirect injection, the 4BD1 is direct injection

 

[Eric Winkworth]

Automatic swap *cringe*

 

[Combat Chuck]

Automatic swap *cringe*

x10

However, the difficult length of a truck transmission (700R4, 4L60, 4L80, A440, Ferd) is far offset by it's advantages over a mediocre dinosaur car transmission (TH350)
To me, a three-speed auto trans makes about as much sense as buying a blind, 3-legged horse.
That's a gearbox designed for V8 motors, pure and simple. A V8's power-band is nice and broad, and can compensate for the lack of gearing. Inline motors, such as the I4 4BD/4HE1(especially a diesel motor, with it's considerably lower red-line) do not have such luxuries, and the three-speed will be debilitatingly bad for your diesel swap; your wife would be able to teach Volvo's a thing or two about the word: "slow."

What about building your wife and 4BDJ45?

 

[mudmud]

65" from fan mounting flange to back surface of rear output flange.

The 4BD2 is indirect injection, the 4BD1 is direct injection

@Astr: Yeah, that's what I meant, just fingers typed it wrong... lol Thanks for the numbers, looks like to me there should be room for a drive shaft... without having to move the axels back.... There seems also that I could move the whole drivetrain forward if I had to a smidge or so but don't know how that would affect the front drive... I guess this is just speculation unless I can get you to give me the engine/trans/transfcase as individual measurements, then I can cad it up and see the best arrangements.... I like the "more hp" of your engine selection, is the 4H much heavier, and I guess the trans is beefier ie heavier??

@Eric: Yeah, yeah.. I get it...

@Combat Chuck: You too! Heh! so between you and Astr I will def go the truck trans way, so I'll look now for a 4HE1 4.8 liter with a Aisin AW450 automatic transmission. As far as the idea of a 4BDJ45, well ahem.... she likes the look of the FJ40.... and that's that! lol

I once helped my friend put in a 327 chevy in the front of a 65 VW, basically a frame/engine w/ a body on top... fun to see people reactions.... most thought it cool, a few diehard vw fans were outraged! lol

This ought to be fun!

 

[dohcdelsol93]

I get to test drive my 4bd1t fj60 Tom. The IdS kit makes this an easy swap. Forget the th350 tranny, unless you have 44" tires you need the overdrive. With no overdrive don't expect to drive over 50. The 700r4is a good tranny stock for low hp engines, if built she can handle some abuse. Add a tranny cooler and have her built by a reputable shop and she will serve you well

 

[Nexxussian]

If you go with a 4B variant and the IDS adapter, a 4L80/85E would be a better trans strength wise.

Initial cost is more than a 700/4L60, but it should only require refresh and updating it to the current factory service revision. That will almost certainly be cheaper than the level of reinforcement of any 700R variant is likely to cost.

I don't know how it will compare for length with the 700s though.

 

[fueg0]

Subscribed. My wife LOVES my FJ40, but she despises anything with a manual transmission. I'll be keenly watching this thread.

 

[astr]

If you do go with the 4HE1/AW450, you still need to source a A440F for the output shaft and the split T-case. You will have to make up some spacers and mod the parking rod. Also, the starter issue has not yet been resolved.

IIRC, the 4HE1 only weighs about 80 lbs more than the 4BD1T (785 lbs w/acces for the 4BD1T). The engine & AW450 bellhousing is about 5" shorter than a 3FE & A440F bellhousing. So for a swap into an FJ62, with the rear mount in stock location, you end up with 5" more space up front (enough to move the radiator back and stick an intercooler in there)

 

[mudmud]

So as to not be bouncing around so much it seems to me that my choices are:

1) 4HE1/AW450 with a A440F for the output shaft and the split T-case

2) 4BD1T to a 4L80/85E then what ever Advanced Adapter to the T-case

I must admit to like the direct injection of the 4BD1T and I like the bigger HP of the 4HE1....

So now I must meditate!

@dohcdelsol93: whoo hoo! Have fun testing! Any Trans I do I will add a cooler onto, it's just too easy to do and good insurance! That's what I figured with the TH350, but just saying... it's the shortest... but I do need OD!! My current manual setup hates the freeway...

@Nexxussian: thanks for the info, I it's good to know which trans is stronger. I have no experiance with any of them really....

@fueg0: And THAT is why I'm doing this... for her. If it wasn't for her we would not have bought this FJ40, it was her liking the look of it, she found it on Ebay! My only involvement was I had money to buy it and ship it to Alaska from NJ!!

Now it's time for me to have fun! I guess I like mechanics more than driving... lol

@astr: I like the extra HP, and I like the strong transmission. That I'd have to go thru the splice project is a consideration... it will take time. And I am wanting to streamline this project.

So the option 2 sounds quicker to do. I'm beging to lean that way.
Any feed back on costs? Will the Option 1 be significantly more expensive due to being newer? Cost is not everything but a consideration...

I am open to opinions! Help me help mysef! lol

Later,

Carl