Hello, looking for 80 40 chassis swap info and advice. I can’t push a clutch anymore so if I’m going automatic I might as well go all the way.

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Snakepit

Snakepit

Joined
Nov 25, 2025
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1
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18
Location
Idaho usa
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pbgbottle said:
Check out Aqualu they make a fj40 body that will bolt onto a 80 series chassis. 80 series chassis is wider than the stock 40. Aqualu makes a custom wide body 40 to bolt onto the 80 chassis.
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Thank you for your reply. That would be an easier way to go about it. I looked their website over , they have cool stuff. How would you go about titling the project once it’s done? No vin / off road use only. Or did I not find the tubs. I’m looking through the forums for people who have done similar things.
 
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The title would follow the frame, so it would technically be a 80 series. This would be dependent on the state it was registered in….
 
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archie73 said:
The title would follow the frame, so it would technically be a 80 series. This would be dependent on the state it was registered in….
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Unfortunately that opens up a whole can of worms. 80 if newer than 1994 had air bags. Sure other safety features as well. Then there is emissions. That might limit use and later sale.
 
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Here is my 45/80 build. 1uz v8 and 5 speed manual in it. I used to have the 5speed auto from the 100 series, but in my honest opinion, no matter what engine you plan on using, if you want an auto box, get a ZF hp80. It is hands down the best auto for any swap
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Living in the Past said:
Using a different body and frame. I would sell the whole 40 and start from scratch. Would come out ahead selling and sourcing the body parts you need.
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While the Aqualu 40/80 body is pricey, I think it’d definitely pay for itself in the long run. Personally any concerns of keeping it “original “ are out the door in this type of build anyways. The aluminum tubs may not be true original, but they have advantages over the old steel ones: sheer strength, clean slate, no dents and already widened to fit the 80 chasis.

Coworker sent me this the other day. Seemed like a good deal if you’re interested
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Real question is do you have a 80 chasis to build off of? I’m also in Idaho and Ive been keeping an eye out for a 80 cheap enough to throw the body away. They are tough to find.
 
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archie73 said:
While the Aqualu 40/80 body is pricey, I think it’d definitely pay for itself in the long run. Personally any concerns of keeping it “original “ are out the door in this type of build anyways. The aluminum tubs may not be true original, but they have advantages over the old steel ones: sheer strength, clean slate, no dents and already widened to fit the 80 chasis.

Coworker sent me this the other day. Seemed like a good deal if you’re interested View attachment 4092839
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Wasn't against going the 80 series route. Financially would make more sense selling a complete 40 instead of taking parts off it. Only body parts would be the front door and possibly the fenders that wouldn't need mods. For a year round use in Idaho a hard top for the winter would make more sense. Unless vinyl windows have gotten better they are brittle in cold weather. Back in the mid nineties bought a brand new Kayline top. During the summer in Northern Arizona just after sundown if the side windows weren't rolled down had to be careful rolling down.
 
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Another question you need to ask yourself is what motor you want to use. If you're planning on running the 1FZ, it is too far forward where its mounted in the 80 frame to keep the front wheels centered in the wheel wells to be able to run a front radiator. So now, you're moving the motor/trans/transfer case back 5-6", custom drive shafts, modifying exhaust, etc. At that point, you might as well do an engine swap.

The 40 on 80 is awesome.... I love my setup, but its a TON of work. Nothing fits where it should, and everything is from scratch.

Not trying to be rude or imply anything, but if you can't push the clutch in, I imagine you're going to hire most of this work out. At $100-200 an hour shop rate, it's going to be a $100k truck really quick!

Good luck with the project!

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Living in the Past said:
Unfortunately that opens up a whole can of worms. 80 if newer than 1994 had air bags. Sure other safety features as well. Then there is emissions. That might limit use and later sale.
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Yep that’s a problem, also found that those tubs are 63 3/4”. So would be better to use my 70 fj40 and cut the 80 frame down. I can title it as the 70 and dodge the airbags. Sounds easy if you say it really fast
 
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I have a 97 frame and locked axles with title. Carcas body shell will go with it. DM if interested. I am in Dallas.
 
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UZJ40 said:
Another question you need to ask yourself is what motor you want to use. If you're planning on running the 1FZ, it is too far forward where its mounted in the 80 frame to keep the front wheels centered in the wheel wells to be able to run a front radiator. So now, you're moving the motor/trans/transfer case back 5-6", custom drive shafts, modifying exhaust, etc. At that point, you might as well do an engine swap.

The 40 on 80 is awesome.... I love my setup, but its a TON of work. Nothing fits where it should, and everything is from scratch.

Not trying to be rude or imply anything, but if you can't push the clutch in, I imagine you're going to hire most of this work out. At $100-200 an hour shop rate, it's going to be a $100k truck really quick!

Good luck with the project!

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Not offended at all, sage advice. I do own a fab shop so the sweat equity, parts and consumables will keep it a little more affordable. For the engine I’m looking at a 97 triple locked 80 and using engine, transmission, transfer case and axles. I have some experience lengthening and shortening farm trucks. I know this will be a nightmare project to some but it is the kind of work I enjoy. Besides that I haven’t been in the hills for three years now and I miss it. I want fuel injection because the places we go are very off camber and steep. I absolutely love your truck, it is beautiful! You did an awesome job.
 
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Vossie said:
Here is my 45/80 build. 1uz v8 and 5 speed manual in it. I used to have the 5speed auto from the 100 series, but in my honest opinion, no matter what engine you plan on using, if you want an auto box, get a ZF hp80. It is hands down the best auto for any swap
View attachment 4092825
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Man I love those trucks! I’m going to have to have one “someday “ thank you for the tip on the transmission I will do research on it. Definitely love the input, thanks again.
 
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archie73 said:
Real question is do you have a 80 chasis to build off of? I’m also in Idaho and Ive been keeping an eye out for a 80 cheap enough to throw the body away. They are tough to find.
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Dm me and I can help you find one when you’re ready. And no I haven’t purchased an 80 yet, to many rigs in the yard I have to clear a couple out before I make that purchase.
 
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