FJ40 to HJ40 Build

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Hey Jay, I will come over and help you slow things down as you know I will just talk a whole buntch....


If I can help give me a call and I will try to get down thier.


Course I was of no help when you called about the tcase gears, should of called Marlin.....


Should pull stumps out when yur done..


Rob
 
looks great jay can't wait for shakedown run.
 
Oh don't you make me come down thier and get on a chair and kick your ass.


Getter done....


This weekend is shot, next one should work if you want some help.


Rob
 
Sorry Guys, been to lazy to post anything. Well the project didn't get my full attention this weekend. With some tweeking finally got my final engine position, so mounts are welded up and started on the tranny mount. But before I finished that I ran the brake line and fuel line. Also got to rerun the front air line, kind a got melted on last outing with the IRC guys. This weekend I will take more pics and should have the engine finally mounted. I am also gonna have to do some mods with the rad location, its gonna be tight.

Jay
 
Well I got off my but this weekend and finally got back at it. These first pics are of a stock HJ60 Xmember and then the modifications I had to do to make it work. What I had to do was move it back towards the flange to have clearance for the drive shaft. Because I had to move it back it half blocked the tranny drain hole, so I inserted a half piece of tube to make a channel for a more controlled drain. I decided to try and mount it to the bottom of the frame. Time will tell if this works.
Stock_HJ60_Xmember.webp
Modified_Xmember.webp
Modified_Xmember4.webp
 
Well the next piece was the clutch witch I got in and working but didn't take any pics. Also I removed one of the heater tubes for the rear heater and plugged the hole. I also attached my heater lines up. So after this I thought I was moving until I fitted the radiator then everything came to a grinding halt. As you will see the problems are the bottom hole aims at the PS pump and the upper one is at the wrong side. So with these problems I either have to look at moving the holes, custom rad, or I even mocked up a FJ60 rad with hole relocation. Still working on this one.
FJ40_Bottom_Inlet.webp
Thermostat_Housing.webp
 
Will that t-stat housing rotate 120 degrees? Is the bolt patern concentric? Still won't solve your lower rad hose problem but might open up more options for rads...
 
The other concern I had was where the PS pump return line was facing. This was solved by shear luck when I went to the shed looking for the bango fitting for the high pressure side of the pump I noticed that another one had a different fitting so I swapped them and they fit.
2Returns.webp
Stock_PS_Return.webp
3L_PS_Return.webp
 
FLYINGLOW said:
Seapotatoe needs that ps fitting!!!
Click to expand...



Haha, yep I do...


Don't chuck that little thing, I may bribe you for it next time I stop by...


I got a 60 rad to fit into my fj55 frame by trimming the sides of the bracketry down.( I think 55 and 40 frames are the same width at the front...?)

clears by about 3/16 on each side, but ok otherwise, tho you might have issues with the headlight buckets?
 
So here is a quick pick of the slave cylinder. It is a HJ60 one which is self adjusting so you will notice no return spring on it or adjuster rod.
HJ60_Clutch_Slave.webp
 
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