H42 four speed manual transmission into 1992 FJ80

[bhmmapping]

I ended up running a support bar to the lower part of the dashboard, it flexed a lot without it. I couldn't find that hole, I bet it is there though.

 

[ThePookieBear]

Once you get everything ironed out, I'm curious about how it cruises at around 60 or so. 65 tops. Where I'm living now the speed limits are crazy low, but I also drive about 150 highway miles twice a week. So I'd still need highway speed capability. Keep us posted. . This is awesome.

 

[retrofive]

All I can say is nice job!

 

[uabericm]

I'm going to keep this simple...I rode in this Cruiser prior to the swap and it was sluggish. However after the swap, this truck is awesome. I cannot wait to ride shotgun on the next trail ride.

Good job.

 

[fjdemon]

Nice job! Manuals rock!

 

[bhmmapping]

I should have it on the road by the end of the week, I've got the front diff out now to install the aussie locker and am doing a mini front end job in the process. I pulled the knuckles off with the spindles and rotors attached and will put it back together with marlin inner axle seals, longfield knuckle wipers, new TRES and the aisin manual hubs.

 

[Atticus]

Any update, Matt? This project is awesome.

 

[bhmmapping]

the front end is still in pieces in the garage. I installed the front Aussie last night, it was a little more involved than I originally thought. I don't know why I thought it was going to be simple like the rear. I was going to do a write-up, but this covers it perfectly:

Aussie Locker

The only differences were that I didn't have to file my case, there was plenty of clearance, and I marked the adjusters and case with a center punch with two marks on the right side and one on the left in case I got the pieces mixed up. I didn't clean things up enough to use a sharpie marker like he did.

This is when I knew it was going to be harder than I had originally planned. you can see that the crosspin is blocked by the ring gear:



In pieces on the welding table:



Aussie in place:



hopefully I can get the front axle together this weekend and start driving it on the highway next week.

 

[Land Speeder]

damnit man!
I got my front Aussie waiting on the truck.... but now you're scaring me...
j/k... but it does look like alot of unwanted work...

 

[motorsargeT]

I just put an aussie in the front of mine. A bit of extra work but worth it in the end. Hubs look cool on an 80!

I thought I was about done with my build but every time I see this thread pop up it makes me think it will keep going.

 

[Land Speeder]

I thought I was about done with my build but every time I see this thread pop up it makes me think it will keep going.

ain't that the truth! Matt doing this is the exact reason I went and sought out a 3FE just so i could do this + crawlbox... and there's your 80 crawler.

 

[bhmmapping]

Just a quick update for those who asked about highway cruising. I finally got the front end back together, and drove it to work on the interstate today. First, the speedometer is off by around 8.5%. reading 55 I am traveling 60. At 60 it is running around 2600 rms, 70 is just under 3000.

I have some kinks to work out still. Mainly, the twin sticks transmit noise at highway speeds, I thought they might since I did not use a bushing. Also, it still feels a little darty, but I am going to take it to get an alignment since I just replaced the TREs. I also added a front spacer to compensate for the extra lift I gained in the rear and can tell I am low on caster with the blue bushings now. I will update after I run through the first tank of gas.

 

[bhmmapping]

Just a quick update on the gas mileage after the conversion. I have now gone through three tanks of gas, mostly in town driving, and all three came in at 12.3 mpg almost exactly. Before the conversion I was usually getting 10.5 - 12. So there was a little improvement but it certainly won't pay for itself any time soon. It sure is fun to drive though.

 

[brian]

i did'nt read the whole thread, so pardon that.
everything looks tight, but why with the 4speed and not a 5spd?

 

[Cruiserdrew]

i did'nt read the whole thread, so pardon that.
everything looks tight, but why with the 4speed and not a 5spd?

My guess is:

4 speeds are basically free/given away.

5 speeds are spendy-$2500 or so these days.


Once you prove the mod, you can always go back and swap the tranny later.

 

[bhmmapping]

My guess is:

4 speeds are basically free/given away.

5 speeds are spendy-$2500 or so these days.


Once you prove the mod, you can always go back and swap the tranny later.

That's exactly right. My original plan was to just go with the 4 speed until I was sure I liked the manual, and then move up to a five speed. Now I am leaning towards 37's for the lower rpms on the hwy and a crawler box for offroad.

 

[bhmmapping]

Well my ghetto clutch bucket that I hacked together from the 60 bucket finally collapsed on me so I had to build a proper one. The factory 80 bucket bolts to the dashboard somehow, but I couldn't find that hole on my truck. I ended up making a support plate for the engine side of the firewall and building a new piece for the inside. These are the only pictures I have for now, I will try and take some with the better camera now that it is installed.





It is amazing how much smoother the truck shifts now.

 

[bhmmapping]

I also built a new skid plate. With the transmission crossmember attached to the front of the transmission on the H42 everything looked extremely vulnerable hanging out back there. I think it should be ok now, although the gear noise is a little more noticeable with this bolted on. I will try and take an installed pic of this too.

 

[bhmmapping]

Master cylinder and support plate for clutch pedal bucket - Some brake fluid leaked out and took some of the paint off.



Clutch pedal bucket installed:



Skid plate installed.

 

[Eicca]

Looks good! Awesome metal skills too