disclaimer - i have read dozens and dozens of threads on these topics, but still havent quite found the answer. thanks to Beno, 70's guy, toolsrus, tor, romer, and many more for lots of ideas, info and knowledge.
BLUF: i am wanting to pursue a v8 conversion with 5 speed manual transmission, as well as a dual transfer case for my 1997 fzj80. the dual transfer case is the difficult part...
WANTS: Main reasons are to get around the usual 80 series weaknesses: power and range. I realize that for the cost of one of these conversions i could buy a small island (or a decent used 200 series and then a cheaper/beater dedicated crawler like a 1st gen 4runner), but i want to keep the 80 for the third row seating (i have a 3 kids and 1 more on the way), solid axles and lockers (we do some low risk crawling), but also be able to do some longer roadtrips. I have a 6" slee lift with 37s and (a 1" body lift that i plan to remove). i have 176,000 miles on the truck so far. it runs great, just sucks down the gas and i spend more time filling the gas tank than wheeling, all the while getting passed by Prius' towing tear drops....
EXPECTED RESULT: With the V8 I would be able to get 80 mph quickly and cruise there, while potentially getting much better fuel economy/range. With the manual tranny it would be more fun while driving, and with a dual case compensating for my lack of crawling ability with a stick shift, but also allowing a much more controlled, safer setup for technical wheeling with my family in the back of a massive whale of a cruiser. it would go from a 38.8:1 total gearing to somewhere close to 200:1. Ideally also an engine swap would make the setup closer to 'new vehicle' drive train reliability, rather than hoping my 1FZ-FE doesn't blow up (head gasket) on our next trip to the desert. And of course paying big money to a professional conversion shop allows them to do all the hard electrical work on harnesses, and making A/C, dash, buttons, equipment all still remain functional. SUMMARY: an 80 series with 200 series power and double the range.
PLANS:
a) already purchased, but still need to install: bigger fuel tank and marlin cruiser gear t-case gears. wont solve all the problems but it helps with range and gear ratios. I'll probably also be installing dynamatt to quiet things down a bit.
b) currently in the lead is sending the truck to dieseltoys in san antonio for them to swap in a import half cut 4.5L toyota D-4D twin turbo diesel v8 1VD-FTV engine, and a R150F transmission from a 70 series. hoping to also get a dual case/blackbox/Advanced adapter/marlin tacobox/etc, but i am not sure if it will all workout. The current plan would be to use the stock transfer case (HF2AV) to keep all wheel drive, ABS functionality, etc. Another option would be the 4.2L 1HD-FTE turbo diesel with H55F, also not sure about dual case. More power with the twin turbo V8. new overseas vehicle would hopefully mean better parts support than a 25 yr old 1HDT conversion.
c) backup expensive conversion plan would be to go to a different outfit (Proffitts, Torfab, TLC, etc) for a gas V8 swap, some sort of domestic 5 speed - maybe NV4500 or NV5600 6 speed, and hopefully some sort of dual case. Not sure exactly which parts and pieces. Domestic V8 would allow for even better parts availability, but might also require part time t-case, which causes ABS and AWD issues. i'd like to keep all wheel drive and ABS.
also, just for fun - i would also consider some sort of a hybrid family roll cage, and a 'spare wheel well area' storage box.
QUESTION:
does anyone know the details about how a 70 series engine and transmission could work out with the stock transfer case and a dual transfer case/box?
or a different transfer case? maybe from a VDJ79
howabout a 1HDTE 4.2L turbo diesel with H55F 5 spd and dual case?
BLUF: i am wanting to pursue a v8 conversion with 5 speed manual transmission, as well as a dual transfer case for my 1997 fzj80. the dual transfer case is the difficult part...
WANTS: Main reasons are to get around the usual 80 series weaknesses: power and range. I realize that for the cost of one of these conversions i could buy a small island (or a decent used 200 series and then a cheaper/beater dedicated crawler like a 1st gen 4runner), but i want to keep the 80 for the third row seating (i have a 3 kids and 1 more on the way), solid axles and lockers (we do some low risk crawling), but also be able to do some longer roadtrips. I have a 6" slee lift with 37s and (a 1" body lift that i plan to remove). i have 176,000 miles on the truck so far. it runs great, just sucks down the gas and i spend more time filling the gas tank than wheeling, all the while getting passed by Prius' towing tear drops....
EXPECTED RESULT: With the V8 I would be able to get 80 mph quickly and cruise there, while potentially getting much better fuel economy/range. With the manual tranny it would be more fun while driving, and with a dual case compensating for my lack of crawling ability with a stick shift, but also allowing a much more controlled, safer setup for technical wheeling with my family in the back of a massive whale of a cruiser. it would go from a 38.8:1 total gearing to somewhere close to 200:1. Ideally also an engine swap would make the setup closer to 'new vehicle' drive train reliability, rather than hoping my 1FZ-FE doesn't blow up (head gasket) on our next trip to the desert. And of course paying big money to a professional conversion shop allows them to do all the hard electrical work on harnesses, and making A/C, dash, buttons, equipment all still remain functional. SUMMARY: an 80 series with 200 series power and double the range.
PLANS:
a) already purchased, but still need to install: bigger fuel tank and marlin cruiser gear t-case gears. wont solve all the problems but it helps with range and gear ratios. I'll probably also be installing dynamatt to quiet things down a bit.
b) currently in the lead is sending the truck to dieseltoys in san antonio for them to swap in a import half cut 4.5L toyota D-4D twin turbo diesel v8 1VD-FTV engine, and a R150F transmission from a 70 series. hoping to also get a dual case/blackbox/Advanced adapter/marlin tacobox/etc, but i am not sure if it will all workout. The current plan would be to use the stock transfer case (HF2AV) to keep all wheel drive, ABS functionality, etc. Another option would be the 4.2L 1HD-FTE turbo diesel with H55F, also not sure about dual case. More power with the twin turbo V8. new overseas vehicle would hopefully mean better parts support than a 25 yr old 1HDT conversion.
c) backup expensive conversion plan would be to go to a different outfit (Proffitts, Torfab, TLC, etc) for a gas V8 swap, some sort of domestic 5 speed - maybe NV4500 or NV5600 6 speed, and hopefully some sort of dual case. Not sure exactly which parts and pieces. Domestic V8 would allow for even better parts availability, but might also require part time t-case, which causes ABS and AWD issues. i'd like to keep all wheel drive and ABS.
also, just for fun - i would also consider some sort of a hybrid family roll cage, and a 'spare wheel well area' storage box.
QUESTION:
does anyone know the details about how a 70 series engine and transmission could work out with the stock transfer case and a dual transfer case/box?
or a different transfer case? maybe from a VDJ79
howabout a 1HDTE 4.2L turbo diesel with H55F 5 spd and dual case?
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