Forge Specialties, An FJ62 gets a 5.3 LS V8

[35inchoverdrive]

For getting the placement and angles correct with the motor mounts, did you use the stock cross member in the stock location? Any spacers to lower it?

We always try to position the crossmember in the stock location, if possible, so that the stock driveshafts can be retained. This is a cost-saving move, but more importantly, it makes sourcing replacement parts down the road much easier.

The stock mounting holes for the transmission mount needed to be moved forward slightly, due to the positioning of the adapter.

...stock crossmember.

...making the first cut.

 

[35inchoverdrive]

After chopping a chunk out of the crossmember, we mocked everything up with the transmission mount. You'll notice that the transmission mount has been cut in the middle to compensate for differences in width between the mount and the adapter mounting holes. We attributed this to inconsistencies in the aftermarket transmission mount, but the Toyota one was coming up as "not available" when we were doing this swap.

...tacking some 1/4" plate in place.

On the bottom side of the crossmember, we built a ramped section and punched out two large holes for hardware access. We tried to mimic the stock look as much as possible.

 

[35inchoverdrive]

...top of the modified crossmember.

...bottom of the modified crossmember.

...after a dusting of satin black.

 

[gregnash]

Nice! Hopefully you boxed in the inside so that way if for some reason the nuts happen to back off then you don't have it rattling all over the place in there. And hopefully the holes are large enough to fit a decently fat impact socket in there without issue.

 

[GLTHFJ60]

I thought the point of using the factory crossmember was so that you didn't have to move the transmission location, so that the driveshafts could remain the same length. Now that you've modified the factory crossmember, won't you need custom driveshafts? I know you didn't move it much, but the stock slip joints in the shafts didn't have that much travel.

 

[FJ60Cam]

I thought the point of using the factory crossmember was so that you didn't have to move the transmission location, so that the driveshafts could remain the same length. Now that you've modified the factory crossmember, won't you need custom driveshafts? I know you didn't move it much, but the stock slip joints in the shafts didn't have that much travel.

The adapter doesn't place the mount in exactly the same location. The t-case doesn't necessarily have to move.

 

[GLTHFJ60]

The adapter doesn't place the mount in exactly the same location. The t-case doesn't necessarily have to move.

You're right, it would make sense if the crossmember was modified to keep the t-case in the same location.

 

[35inchoverdrive]

Nice! Hopefully you boxed in the inside so that way if for some reason the nuts happen to back off then you don't have it rattling all over the place in there. And hopefully the holes are large enough to fit a decently fat impact socket in there without issue.

Those that fail to tighten bolts must suffer the consequences. A rattly crossmember is a small price to pay for not torquing down the bolts that hold the rear of your drivetrain in place.

Now that the drivetrain is mounted...we pull everything back out...for a round of fit an finish work.

 

[Skrewball]

With the adapter, the transfer case is positioned really close to stock. The driveshafts are in a good position for slip travel.

The adapter is designed for the late FJ 60 mount and not the 62 mount, so modifying the stock crossmember is necessary.

The holes in the bottom of the "new" crossmember are a touch small...but functional!

 

[Grumpyhead12]

*The picture quality will temporarily take a nosedive. There was a dark time in the shop where we only had a really crappy camera. It gets better, I promise.*

We stripped the intake and accessories off. This guy really needed a bath.

View attachment 1221618

After an initial scrub down(so we didn't get GM on us every time we touched it) we used our hotrod '79 Toyota forklift to assist with mockup.

View attachment 1221619

These LS engine mount plates are a good start to fabbing up some custom mounts.

View attachment 1221620

What are your thoughts on fuel delivery? Are you planning an in-tank pump for the Stock 62 tank or external pump?
David

 

[mattn]

Woah. Awesome work! Sub'd.

 

[gregnash]

What are your thoughts on fuel delivery? Are you planning an in-tank pump for the Stock 62 tank or external pump?
David

Think back towards the beginning Nate stated that they were planning an in-tank setup. I could be wrong though.

 

[FJ60Cam]

...The early parts are often fun and we really love what we do...

Just had to quote this part for truth. The early parts parts of a swap are exciting and dramatic. And is actually the easy part. The swap really doesn't even start until the drivetrain is locked into place.

Nice work so far, looking forward to the rest

 

[Grumpyhead12]

Think back towards the beginning Nate stated that they were planning an in-tank setup. I could be wrong though.

I looked an no mention I could find. I found my answer from Tanks Inc. though; very helpful.
David

 

[Skrewball]

Stock 62 pump is quite capable. We kept the original pump and watched it closely under heavy load to make sure the pressure didn't drop much.

If the stock pump wasn't up to the task, we were planning to install the supra pump that bolts in.

The 80 we did with an LQ9 6.0 is also running the stock pump. He's got 30K on that swap and no issues. Toyota's fuel setup is capable of quite a bit more than stock demand!

The Tacoma we did with a mild cam LM7 5.3 did need a different pump. It got a Tundra pump that bolted in to the stock tank assy.

 

[Grumpyhead12]

Stock 62 pump is quite capable. We kept the original pump and watched it closely under heavy load to make sure the pressure didn't drop much.

If the stock pump wasn't up to the task, we were planning to install the supra pump that bolts in.

The 80 we did with an LQ9 6.0 is also running the stock pump. He's got 30K on that swap and no issues. Toyota's fuel setup is capable of quite a bit more than stock demand!

The Tacoma we did with a mild cam LM7 5.3 did need a different pump. It got a Tundra pump that bolted in to the stock tank assy.

Thanks.

 

[35inchoverdrive]

While the drivetrain is out, the engine mounts get burned in.

Then some extremely unexciting engine bay scrubbing takes place. Pre-scrub...

It cleaned up nicely.

 

[35inchoverdrive]

New fuel line plumbing for the engine bay is up next.

...bending up some hard lines.

...mounting the GM fuel filter.

 

[Elbert]

nice

 

[MANUCHAO]

I spot a HELTON heat exchanger... !!!