You are probably running in the same problem I had. I had to use a Wilwood brake master in 7/8 size to the stock slave to get the clutch to work. Stiff pedal though even though it broke in and isn't so bad now.
FJ60 Diesel conversion
- Thread starter browndog
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Don't drop the tank!
No need to drop the fuel tank. There is a handy access hole in the center of the rear cargo floor specifically for servicing the fuel sending unit. Just remove the rear capet trim, then roll the cargo carpet forward. You'll see the ~6" square hatch in the middle of the floor. Remove 2 phillips screws. You'll have to pry it loose because the weatherstrip is petrified and holding it in place.
I have never replaced a fuel sender in a FJ60.
I've seen 2 that were stuck from sitting too long. Once the sender was removed and popped loose, it decided to resume normal operation.
I've seen many more that had corroded contacts at the 2-pin connector. Use a nail file and/or steel brush to clean things up. If necessary, cut the stock connector off the wire harness and replace w/ 2 standard push on connectors. Use lots of Ox-Gard to keep it from happening again.
Warning! This thread has been hijacked. Please stay calm.Gumby said:
No need to drop the fuel tank. There is a handy access hole in the center of the rear cargo floor specifically for servicing the fuel sending unit. Just remove the rear capet trim, then roll the cargo carpet forward. You'll see the ~6" square hatch in the middle of the floor. Remove 2 phillips screws. You'll have to pry it loose because the weatherstrip is petrified and holding it in place.
I have never replaced a fuel sender in a FJ60.
I've seen 2 that were stuck from sitting too long. Once the sender was removed and popped loose, it decided to resume normal operation.
I've seen many more that had corroded contacts at the 2-pin connector. Use a nail file and/or steel brush to clean things up. If necessary, cut the stock connector off the wire harness and replace w/ 2 standard push on connectors. Use lots of Ox-Gard to keep it from happening again.
Rob - I'll buy ya' lunch. Save some work and use the hoist some Saturday. that might make the drive worth it. 
thanks, Jim. You da man. I was wondering if the 60 had an access panel. I know the 80 and most late model japanese cars do, but I thought they went to that when the fuel pump started appearing in the tank. I will investigate in about an hour right before I start a cool new vac pump mod i think will get the stock tach to read on a diesel.
thanks, Jim. You da man. I was wondering if the 60 had an access panel. I know the 80 and most late model japanese cars do, but I thought they went to that when the fuel pump started appearing in the tank. I will investigate in about an hour right before I start a cool new vac pump mod i think will get the stock tach to read on a diesel.
I've found that a 3/4" Wilwood clutch master will work where a stock Toyota one won't. Even though they have the same bore size. I guess because the Wilwood has a longer stroke. Nice light pedal pressure.
Gumby said:
you could have sent me a PM on this since i am around the corner.....dummy.
seriously, if you ever need anything like that or just need a hand, don't hesitate to PM me or just stop by....
I drove by. Your cruiser wasn't there. Any time you're driving by, stop by and drive a diesel.
The vacuum pump I have is a post 86. FL's is pre-96. I called on one, but they want a bunch plus core. I will check the bone yard at my next opportunity.
FL- I see your has the firewall mounted filter. Do you have the square filter on the intake as well? The vac pump might interfere with mine.
The vacuum pump I have is a post 86. FL's is pre-96. I called on one, but they want a bunch plus core. I will check the bone yard at my next opportunity.
FL- I see your has the firewall mounted filter. Do you have the square filter on the intake as well? The vac pump might interfere with mine.
I think I can do this Saturday. I do have some add-a-leafs I need to install.... Seriously, I'd be happy to head out there to meet you and Patrick (if he's up for it).
PM if you guys are interested in test drives and lunch.
Rob
PM if you guys are interested in test drives and lunch.
Rob
Patride and Chitown came by today to compare 60s, so I called the wife to come bring the diesel back up to the shop. She called about 10 minutes later broken down on the side of the road. No clutch.
Rob dropped his valve adjust and jumped right in pulling the week old super special Downey clutch.
The first pic is a far to common sight in my shop. The second is the reason why. We threw in another disc. If this one holds together, I'm going to be rather upset with Downey.
Rob dropped his valve adjust and jumped right in pulling the week old super special Downey clutch.
The first pic is a far to common sight in my shop. The second is the reason why. We threw in another disc. If this one holds together, I'm going to be rather upset with Downey.
well that sucks....but you pretty much predicted it right when you towed it up there yesterday. i was wondering what the outcome was....
i probably had much more fun toting around the kid and her two friends yesterday to the mall and to the movies...god i wanted to drive off the road into on coming traffic a few times...
i probably had much more fun toting around the kid and her two friends yesterday to the mall and to the movies...god i wanted to drive off the road into on coming traffic a few times...
- Thread starter
- #73
Back to the post
The 13BT/H55f swap is done! After 8 days working 8 hours a day we got the motor in and running. Fired up on the first turn of the key. We probably could have finished the job faster, but rookie mistakes and waiting for parts dragged it out a little. Fabbing up the new motor mounts and swapping the front half of the t-case took the most time. Here is a summary of the swap:
1. Got the 2F out in a couple of hours--very satisfying to rip out all of the emissions control garbage.
2. Swapped the front half of the t-case out for a manual t-case. This took some time because we had to fab the shift pin on the manual t-case to match the shift lever from the 2F. It required making another flat notch facing towards the motor. Works great and saved me having to run more vacuum lines and VSV's for vacuum shift.
3. Decided to go with cable throttle rather than linkage. Drilled a couple holes in the firewall, filled the old holes, and now have a really smooth throttle complete with the manual throttle control from the BJ74 mounted n the dash.
4. Dealing with the heater hoses was time consuming, but in the end the setup is pretty clean. My 13BT seems to sit a bit farther back in the engine bay than Stickboys, not sure why, but we made it work.
5. Ran 2 1/2 inch exhaust straight down the passenger frame rail and ported in front of the rear passenger tire. Set up some heat shields where the exhaust gets close to the fuel lines. No muffler. Sounds good and has great flow.
6. Haven't hooked up the glow screen yet but haven't needed it. Will work on that later.
7. I went with a pretty simple filter setup--kept the stock filter and ran a napa inline job in front. I'm running B20 biodiesel now and haven't had any problems. We'll see what happens when I go to B100.
I'm really happy with the swap. The power is great--far more punch than the 2F ever had, especially on long hills in the mountains. It does cause more vibration in the cab and is a little loud, but I'm working on vibration control by running a thin bead of silicone rubber along the face plates in the dash board. For sound control I'll probably install some water heater insulation blanket in the cab and under the hood.
Thanks so much to Sheldon and Greg at G&S for sticking with me through the whole process and to Stickboy for your time, advice and hospitality. I definitely recommend G&S for those of you looking to source a Toyota diesel. G&S--Hope to get you guys on the water sometime!
The 13BT/H55f swap is done! After 8 days working 8 hours a day we got the motor in and running. Fired up on the first turn of the key. We probably could have finished the job faster, but rookie mistakes and waiting for parts dragged it out a little. Fabbing up the new motor mounts and swapping the front half of the t-case took the most time. Here is a summary of the swap:
1. Got the 2F out in a couple of hours--very satisfying to rip out all of the emissions control garbage.
2. Swapped the front half of the t-case out for a manual t-case. This took some time because we had to fab the shift pin on the manual t-case to match the shift lever from the 2F. It required making another flat notch facing towards the motor. Works great and saved me having to run more vacuum lines and VSV's for vacuum shift.
3. Decided to go with cable throttle rather than linkage. Drilled a couple holes in the firewall, filled the old holes, and now have a really smooth throttle complete with the manual throttle control from the BJ74 mounted n the dash.
4. Dealing with the heater hoses was time consuming, but in the end the setup is pretty clean. My 13BT seems to sit a bit farther back in the engine bay than Stickboys, not sure why, but we made it work.
5. Ran 2 1/2 inch exhaust straight down the passenger frame rail and ported in front of the rear passenger tire. Set up some heat shields where the exhaust gets close to the fuel lines. No muffler. Sounds good and has great flow.
6. Haven't hooked up the glow screen yet but haven't needed it. Will work on that later.
7. I went with a pretty simple filter setup--kept the stock filter and ran a napa inline job in front. I'm running B20 biodiesel now and haven't had any problems. We'll see what happens when I go to B100.
I'm really happy with the swap. The power is great--far more punch than the 2F ever had, especially on long hills in the mountains. It does cause more vibration in the cab and is a little loud, but I'm working on vibration control by running a thin bead of silicone rubber along the face plates in the dash board. For sound control I'll probably install some water heater insulation blanket in the cab and under the hood.
Thanks so much to Sheldon and Greg at G&S for sticking with me through the whole process and to Stickboy for your time, advice and hospitality. I definitely recommend G&S for those of you looking to source a Toyota diesel. G&S--Hope to get you guys on the water sometime!
- Thread starter
- #76
Panama:
It was 24 volt. I had the starter reworked for 12V and got a 12 volt alternator with vacuum pump from G&S. I also picked up a tach from a BJ60, although it looks exactly the same as the one in the FJ. The glow screen can be run on 12V, but I haven't hooked mine up yet. When I do I'll probably hook it directly into an ignition wire and use a momentary switch to control time.
The only wiring changes we had to make were related to the alternator. On the FJ the plug coming off of the alternator has two wires, while on the BJ alternator the plug has three wires. We ended up using two of the wires in a plug and running one (the large white wires) directly to the regulator. I can give you more detail if you need it.
As for fuel economy, on the drive home from MT I was pulling a trailer and driving into a serious headwind and still got 19mpg. I'll get you DD mpg estimates soon, but I've already gone 150 miles on this tank and I'm not even halfway through the upper half of the full range. I've definitely found it very tempting to put a little more pressure on the pedal because the turbo is so responsive, but with a light foot I'm sure I'll be over 20mpg.
VTCruiser: Thanks for the props! If you ever find yourself in Oregon, give me a shout.
It was 24 volt. I had the starter reworked for 12V and got a 12 volt alternator with vacuum pump from G&S. I also picked up a tach from a BJ60, although it looks exactly the same as the one in the FJ. The glow screen can be run on 12V, but I haven't hooked mine up yet. When I do I'll probably hook it directly into an ignition wire and use a momentary switch to control time.
The only wiring changes we had to make were related to the alternator. On the FJ the plug coming off of the alternator has two wires, while on the BJ alternator the plug has three wires. We ended up using two of the wires in a plug and running one (the large white wires) directly to the regulator. I can give you more detail if you need it.
As for fuel economy, on the drive home from MT I was pulling a trailer and driving into a serious headwind and still got 19mpg. I'll get you DD mpg estimates soon, but I've already gone 150 miles on this tank and I'm not even halfway through the upper half of the full range. I've definitely found it very tempting to put a little more pressure on the pedal because the turbo is so responsive, but with a light foot I'm sure I'll be over 20mpg.
VTCruiser: Thanks for the props! If you ever find yourself in Oregon, give me a shout.
Didn't see this post until now, Browndog. Congratulations! If you need me to host some install pics for you so they can be linked on this page, go ahead and email them to me at ashuang@telus.net and I can do that for you. Was really good to meet you when you were up here. We'll have to toss some flies sometime. 
- Thread starter
- #78
Thanks Stone!
It was good to meet you too. I appreciated the opportunity to drive your 74 and check the motor out a bit. It feels pretty much the same in the 60. I'll get back to you on the install pics. Most of them are pretty similar to Stickboy's, with a few minor exceptions. I think I'll probably take the approach of sending people pics upon request.
As for fishing, you just let me know when you want to swap trips and we'll work it out. My summer is pretty much full with guiding, but spring and fall are generally good.
Cheers.
It was good to meet you too. I appreciated the opportunity to drive your 74 and check the motor out a bit. It feels pretty much the same in the 60. I'll get back to you on the install pics. Most of them are pretty similar to Stickboy's, with a few minor exceptions. I think I'll probably take the approach of sending people pics upon request.
As for fishing, you just let me know when you want to swap trips and we'll work it out. My summer is pretty much full with guiding, but spring and fall are generally good.
Cheers.
I just got back from fishing eastern Washington for a few days. Couldn't believe how little snow there was on the Snoqualmie Summit. The BJ74 ate up the road as usual. Got my usual 23 US MPG, although I did notice that I smoked a tiny bit more and my 13BT started a little rougher on American diesel. Maybe it was just that one station that had old diesel...it was a Shell station.
- Thread starter
- #80
How was the fishing?
On the diesel note, I think US diesel is just crappier diesel. Mine smokes a little too right at first start up, but after it warms up it doesn't smoke at all. I'm wondering if my fuel settings were set up for sea level and just need to be adjusted for altitude (3600ft).
I don't even want to think about how much I like those 74s.....
On the diesel note, I think US diesel is just crappier diesel. Mine smokes a little too right at first start up, but after it warms up it doesn't smoke at all. I'm wondering if my fuel settings were set up for sea level and just need to be adjusted for altitude (3600ft).
I don't even want to think about how much I like those 74s.....