H42 installed in an FJ62

[93561Cruiser]

This weekend I started the installation of an H42 in my FJ62. I'm using the original transfer case from the FJ62 that's been modified to manual shift. The transmission and bell housing came from a 1984 FJ60.

So far the trans and transfer case have been joined and installed in the cruiser. I came across a few things that people may find helpful it they plan on doing this conversion.

1. The bell housing from a 1984 FJ60 will bolt right on the 3FE motor.
2. Be very careful when using the FJ62 bolts to join the t case and the trans. The bolts may be too long and could interfere with the trans gears.
3. When bolting a T case directly to a transmission (without a spacer) watch out for bearing interference (see photo). I had to remove a small amount of material from the t case to clear the transmission bearing.
4. The early FJ60 cross member bolts on so you just have to drill some holes in the frame. In fact the brake lines already were bent to clear the cross member mount. Maybe the manual trans that goes in the FJ62 in other markets bolts to the same place as the older FJ60's? I'm not sure about the later FJ60 mounts, maybe there work as well.
5. I used the FJ62 trans to t case gasket and just cut the center part out.
6. When converting the FJ62 t case to all manual it's best to have the parts from an old t case. I used both selector shafts, that way I could use the shift linkage from the 84 t case that I had. The low/high selector looks the same but the flat is clocked differently on the shaft. The 2wd/4wd shaft from the FJ62 doesn't have a detent so you need the earlier style shaft. The shaft seal from the early t case will press right in the FJ62 case.
7. The FJ62 t case will have to be drilled and tapped for the 2wd/4wd detent. You need a M15X1.50 tap and a 17/32's drill. A 1/2" drill can be used in a pinch. The case aluminum is very soft and easy to tap.

That's about all for now, I'll post an update when I get back to working on the cruiser.

 

[NocalFJ60]

Good writeup.

 

[lowtideride]

Yulp good info, I ran into all those problems as well. The tranny bearing not fitting thru me for a little loop. I ended up painting it and re-installing the case to find out what was hitting.

 

[93561Cruiser]

New helper for the cruiser

Yesterday I was going to finish installing the clutch cylinders and lines. After a quick trip to the head I came back to the truck to find I had a helper. I was in the middle of something so I didn't notice him at first. I started to pick up the clutch cylinder when he went for it first. He hung out for a while then cruised on off. We have Mojave Greens in and around our office at work so I was a bit startled at first, but once I realized it was a gopher snake I let him hang out and watch.

 

[tcb]

Yesterday I was going to finish installing the clutch cylinders and lines. After a quick trip to the head I came back to the truck to find I had a helper. I was in the middle of something so I didn't notice him at first. I started to pick up the clutch cylinder when he went for it first. He hung out for a while then cruised on off. We have Mojave Greens in and around our office at work so I was a bit startled at first, but once I realized it was a gopher snake I let him hang out and watch.

He'd make a sick pair of boots!

 

[lowtideride]

Odd the other day when me and my bud where working on the 60 we had a bird chase a snake through my yard and into the next and it just kep on going....It was humorous becuase it was a rather large snake and a tiny bird doing the chasing.

 

[lunyou]

that looks like what we call a bull snake in MO

lunyou

 

[Matt60]

my pal mason just moved to tehachapi and started working for scaled composites i belive? don't know if hes into snakes.

 

[93561Cruiser]

H42 in FJ62 update

Didn't get any work done during the week, but today I made some good progress.

I am also replacing the exhaust manifold gasket at the same time. The gasket is probably a good day worth of work. There have been many things that have slowed me down on that part of the job. In fact I'm sure I would be driving the FJ by now if it wasn't for the gasket job I decoded to do.


A few more things learned along the way:

1. Ins' ll the clutch fork and through out bearing as you ins' ll the trans. I tried to ins' ll the clutch fork after I ins' ll the trans. Ended up having to remove the pivot and to do that I had to pull the trans about 1/4 away from the bell housing.

2. I modified the FJ62 trans cover, it was much easier than trying to get the FJ60 cover to fit. I just had to cut the hole for the shifter and open up the hole for the transfer case selector. The best thing would probably be cut the center out of the FJ60 cover anl weld it to the FJ62 cover.

3. The big thing I came across today was the 1984 FJ60 clutch bolt pattern is different than the pattern on the FJ62 pedal bucket. Possibly the later FJ60's have the same pattern as the FJ62.

4. I went to fit the stock FJ60 skid plate and it looked like it was going to fit, but the holes in the frame that lined up didn't have nuts in them. I guess I need to grab a few more riv-nuts from work tomorrow.

The things left to do: Finish the trans cover, reins' ll the carpet, figure out if I need to do much with the wiring so that my engine will s' rt, and finish that gasket job.

 

[lowtideride]

so you figured out how to mount the clutch pedal?

 

[93561Cruiser]

so you figured out how to mount the clutch pedal?

I used the pedal bucket from the 1984 FJ60 donor car. You have to take the dash out and drop the steering column in order to get to all the bolts that attach the bucket. Not too bad of a job. Maybe an hour or two, the biggest thing was redoing the clutch bolt pattern because it didn't match the one stamped in the firewall. I couldn't just buy a later model clutch master because the bucket has the studs in it.

 

[93561Cruiser]

Finally drove the FJ62 with an H42

I drove the FJ62 today with the H42. Everything seems to work well. I did come across a few things while finishing it up.


1. The 1984 front drive shaft has a different bolt pattern were it bolts to the transfer case. I had to use the hub from the 1984 transfer case on the FJ62 transfer case.

2. When wiring up the reverse lights from the manual trans you can use the plug that went to the auto trans temp sensor. There is enough wire and the plug matches. All you need is a couple butt slices.

3. I used the original tunnel cover and cut it up so that the shift boots would bolt to it. Next time I think I would graft the manual trans cover to the FJ62 cover.

 

[93561Cruiser]

4 gear speeds in FJ62 with H42

I checked my FJ62 with stock gears, 31" tires, and an H42 transmission. I used a GPS to find speed and just assumed the factory tach was correct, it may not be but it's the one I have so I'm using it. I checked vehicle speed and engine rpm at several data points to find a calibration formula.

The speed calibration for this setup is: engine speed (rpm) / 46 = vehicle speed (mph)

So:
2000 rpm = 43 mph
2500 rpm = 54 mph
3000 rpm = 65 mph

My FJ62 with the auto trans had a speed calibration of rpm / 33 = mph
So:
2000 rpm = 61 mph
2500 rpm = 76 mph
3000 rpm = 91 mph

If I changed to the H55 trans my speed calibration should be: rpm / 37 = mph
So:
2000 rpm = 51 mph
2500 rpm = 64 mph
3000 rpm = 77 mph

 

[cruiserjunktion]

Nice work!

Do you have any pics of the pedal bucket swap?

 

[93561Cruiser]

Nice work!

Do you have any pics of the pedal bucket swap?

No pictures, but there isn't really much to take photos of.

Remove
-brake pedal
-brake master cylinder and booster
-HVAC ducting under the dash
-unbolt the steering column and lower it down a few inches
-remove the dash
-remove bolts attaching the pedal bucket, there are some right behind the dash so it's much easier to have the dash all the way out.
-the pedal bucket will rotate to the side and come on out
-cut the holes for the clutch master cylinder, use a later FJ60 pedal bucket and master cylinder if you can, the stamping on the firewall should line up then. I used a 1984 pedal bucket and the bolt pattern for the clutch is different.
-now put it all back together

It should take several hours but it's not difficult. While in there you can clean up some of the damage caused by the PO and the radio install hacks that were last behind your dash.

 

[akarilo]

Are you saying that these are the fourth gear speeds/ per rpm for the H42 with 31" tires?

2000 rpm = 43 mph
2500 rpm = 54 mph
3000 rpm = 65 mph

If so, can sombody calculate a 33" tire for me?

Thanks

 

[roundrocktom]

Are you saying that these are the fourth gear speeds/ per rpm for the H42 with 31" tires?

2000 rpm = 43 mph
2500 rpm = 54 mph
3000 rpm = 65 mph

If so, can sombody calculate a 33" tire for me?

Thanks

Simple Distance the tire travels is diameter * PI (3.1415).....
Delta is a ration of 31/33.... about a 6% reduction in rpm....

1880 rpm = 43 rpm
2350 rpm = 54 mph
2820 rpm = 65 mph

What is the OD ratio a FJ62 automatic? 0.70? (Noticed the 91rpm speed drop to 65mph).

Oh... number crunching is done in my head... so if there is a mistake, must be a typo (I hate using
calculators, but like doing mental math for fun... but find I'm slipping if I don't use it... I also drive
my kids crazy when I fill up with gas)

 

[roundrocktom]

Opps, should have kept rpms constant.

Changing 31" tire to 33" tires give 6% higher speeds.

2000 rpm = 46 rpm
2500 rpm = 57 mph
3000 rpm = 69 mph

 

[InsanityIsBorn]

Do you have pics of the transmission swap part. Also what was a list of parts needed to complete this conversion? Did you need a new x-member? any other random small parts and such that you needed? As much info about this would be great!

I'm thinking of doing this conversion to my 88 FJ62, but will put in the split case with the transmission instead of use the one I have now as I have a faulty vaccum diaphragm. hehe . . .

Thanks

-Kiel-