HDJ80 vs. FZJ80 Chassis Differences (1 Viewer)

[GreenPump]

I have recently undertaken a project involving a damaged and somewhat rusty HDJ80 w/ manual trans. I have sourced a very clean and rust-free California FZJ80, with the intentions of painting/restoring the U.S. spec gasser chassis, and swapping over the drivetrain and interior from the HDJ80.

Both trucks are 1993, HDJ80 is RHD, FZJ80 is LHD. I am NOT planning to convert to LHD or use any of the interior parts from the FZJ80, but rather swap these parts from the HDJ80.

I have heard that the frame mounting is already set up to accept 1HD-T engine mounts in 8/92 and later U.S. spec 80 series. Is this true?

Are there any other serious considerations here; I am expecting the firewall and dash internals to be different, but hopefully this can be easily cut/welded from one truck to the other.

 

[mudgudgeon]

On the chassis, steering box mount, panhard rod mount, and associated bracing are RHD/LHD specific.

Now would be the time to convert to LHD. It would be less custom work than converting a LHD chassis and body back to RHD.

I think RHD dash cluster would would swap into the LHD dash.

@BarnFab did a good build thread on his conversion.

 

[GreenPump]

On the chassis, steering box mount, panhard rod mount, and associated bracing are RHD/LHD specific.

Now would be the time to convert to LHD. It would be less custom work than converting a LHD chassis and body back to RHD.

I think RHD dash cluster would would swap into the LHD dash.

@BarnFab did a good build thread on his conversion.

I am digging through BAT threads looking at the front ends of HDJ80s... you are absolutely right. It looks like all axles are right-side drop, but the steering is all swapped. Honestly, if I am going to strip down a chassis, I might as well do the swap....

 

[GreenPump]

on a side note, do the E-locker thirds fit into the housing if the donor vehicle did not have them.

 

[ikarus]

Which body are you using? Probably easiest to just swap the engine/trans and interior (minus dashboard) into the FZJ80?

Maybe I don't understand the question. As noted above the steering is all mirrored on RHD, as are the axle mounts.

 

[Sarmajor]

No, the rear axle housings have slightly different shapes to the gasket area between the E-locker differentials and the LSD differentials. I think that you can relieve the opening on a non loader diff housing but it would be best to get a gasket for the e-locker differential and see how much material has to be removed. On a positive note on a 93 truck most of the required wiring should be present. Not the control module of course.

 

[WiscoPat]

on a side note, do the E-locker thirds fit into the housing if the donor vehicle did not have them.

I recently had front and rear e-lockers installed into the third members of my HDJ81, and they were open/open beforehand. No issues with fitment.

I believe the axle housings are nearly identical to US spec, but the steering components are opposite.

 

[WiscoPat]

I recently had front and rear e-lockers installed into the third members of my HDJ81, and they were open/open beforehand. Well, the rear was factory LSD. No issues with fitment.

I believe the axle housings are nearly identical to US spec, but the steering components are opposite.

 

[mudgudgeon]

on a side note, do the E-locker thirds fit into the housing if the donor vehicle did not have them.

It's doable, but not without modifications.

 

[BarnFab]

I have recently undertaken a project involving a damaged and somewhat rusty HDJ80 w/ manual trans. I have sourced a very clean and rust-free California FZJ80, with the intentions of painting/restoring the U.S. spec gasser chassis, and swapping over the drivetrain and interior from the HDJ80.

I have heard that the frame mounting is already set up to accept 1HD-T engine mounts in 8/92 and later U.S. spec 80 series. Is this true?

You need to use the manual crossmember and it will move forward as opposed to the auto. Chassis is the same so you can use the mounts or just drill it, fits fine. Most stuff is close enough it works fine, even the looms can be made to work.

on a side note, do the E-locker thirds fit into the housing if the donor vehicle did not have them.

Yes and No .. yes they fit but you have to machine grooves to get them to fit and that's why the gaskets are different. Best way to do it if you are redneck is buy gasket and use an angle grinder or mag drill to add the check out. I cheat and use a mill but you don't need to. You will need the axles as well from the e-locker as the splines are longer for the dog to sit on.

93 is touch and go as to what looms it has factory, 94 come with the locker looms in place inside the dash in most cases. Its not a hard conversion you can use the HDJ fuel lines, fuel tank etc . Some parts wont work direct like the clutch pedal but its close enough you can make it work with some love

 

[GreenPump]

I have found a 1995 HDJ80 chassis which had a 1HD-T. It is LHD from south America. Some good options like rear ac, third row, etc. So I think I will use that. Hopefully plug and play on the wiring, I will have to modify the front axle housing from the 95 body, rest should go in easy.

 

[GreenPump]

And another question... are the part time/full time 4wd transfer cases interchangeable onto a manual trans... is there any advantage to the part time? Better fuel economy? Are they both gear driven?

 

[Broski]

The rear axle housing is an easy swap over just move the hole thing over.
The Front like others have said needs modifications including notching, adding some studs and building up the gasket area with welds and than making it flat.
All doable for a home fabricator

 

[Broski]

Let me know if that 1FZFE needs a new home.
If it’s a good runner of course

 

[mudgudgeon]

And another question... are the part time/full time 4wd transfer cases interchangeable onto a manual trans...

Yes, they bolt up. Transfer case pinion housings are different lengths depending on full time or part time, so you'll need the correct driveshafts.
If you're changing from auto to manual, you'll also need to take this into account. Auto trans is longer, so driveshafts need to match the transmission type as well as transfer case type

is there any advantage to the part time?

highly debatable. For a basically stock truck, leave it full time. More saferer!
If you have 3" plus if lift, and suffering vibrations, it can be a way to eliminate driveline vibrations.

Better fuel economy?

no.
Never seen someone with accurate before and after figures to give an objective comparison.
I've run several AWD cruisers in 2wd for months at a time, and no real change in fuel use on the same basic commute/routine

Are they both gear driven?

yes. Full time has a differential in the transfer case. Part time doesn't. It's more of a solid spool. Both fully gear driven.

 

[mudgudgeon]

The rear axle housing is an easy swap over just move the hole thing over.
The Front like others have said needs modifications including notching, adding some studs and building up the gasket area with welds and than making it flat.
All doable for a home fabricator

I did a retrofit of locked oem centres into non locked.
My memory is rear housing needs some mods too, but not a complex as the front.
I did a bit of welding on my front housing to give a but more gasket sealing surface

 

[GreenPump]

Thank you @mudgudgeon for the great info.

I will plan on keeping the full time 4WD since that is what came with the manual trans.

Donor LHD HDJ80 comes with no engine but an A442F in unknown condition and part-time case. I will ditch that and use my full drivetrain keeping manual crossmember. It sounds like there is no advantage to me to switch cases.

 

[GreenPump]

I did a retrofit of locked oem centres into non locked.
My memory is rear housing needs some mods too, but not a complex as the front.
I did a bit of welding on my front housing to give a but more gasket sealing surface

I should be able to keep the rear axle unmodified and swap it right in from the RHD onto LHD chassis. I will have to modify the front axle on the donor LHD chassis to accept the elocker from RHD truck.