Builds Isuzu 4HE1TC into FJ62

[Tapage]

On the A440F, the neutral safety switch also has contacts that turn on the backup lights. On the AW450, the switch is much more complex in that it has contacts for every shift position. These contacts tell the TCM which gear has been selected. I don't have a wiring diagram for the A442F, but I would suspect that the electronic version of the A442F would have a similar switch as the AW450. It also looks like the neutral safety switch on the A442F is mounted on the left (driver's) side of the transmission, same as the AW450. Is that true?

I never saw a AW450 in detail .. but I take the wiring harness of the A442F and use it to do this fancy stuff

when I did my tranny swap ..

IN the top of my mind I don't have the color codes, but aren't hard to found and yes there is a signal for every shifter position in the A442F position sensor .. ( thougt it helps with the solenoids and the ECT and 2nd start )

 

[astr]

I never saw a AW450 in detail .. but I take the wiring harness of the A442F and use it to do this fancy stuff

when I did my tranny swap ..

IN the top of my mind I don't have the color codes, but aren't hard to found and yes there is a signal for every shifter position in the A442F position sensor .. ( thougt it helps with the solenoids and the ECT and 2nd start )

The Isuzu NPR instrument cluster also has the gear indicators like you have. I wouldn't be surprised if the switches are identical. Thanks for the info.

 

[Spook50]

The Isuzu NPR instrument cluster also has the gear indicators like you have. I wouldn't be surprised if the switches are identical. Thanks for the info.

I think if I end up going this route I'd use an Extreme A440f built by Rodney, with the bellhousing and TC from the NPR truck. It'd be great to have some sort of indicator system for that, just for the cool factor of it. Though honestly I'd just be happy if my damn shifter stays in the same spot on the floor!

 

[astr]

I think the gear indicator is an 80 series feature that would work with the AW450. I have no intention of using on my FJ62.

I did do a little more research into the differences between the A440F, A442F, and the AW450. The A440F was strictly a mechanical/hydraulic transmission. The A442F came in two flavors: the early ones were mechanical/hydraulic but later switched to all electronic. The AW450 was always electronic.

Additionally, there are some "heavy duty' differences. The front clutch on the A440F and early gas A442F had 6 disks/plates. On the diesel A442, the later gas A442 and all the AW450, there are 7 disks/plates in the front clutch assembly.

Likewise, the 2nd brake on the A440F has 4 plates/disks while both the A442F and AW450 have 5. (25% more surface area)

I'm not sure how significant these differences are but I suspect that they were made to address some sort of problem.

Certainly, the bellhousing/torque converter swap to the A440F is the easiest approach. My feeling is that with the Rodney upgrades, you will end up spending a bunch more money and probably still end up with an inferior solution. This is yet to be proven.

 

[RAYJON]

I was looking through this again, and noticed something, what is on the turbo side of the motor next to the bell housing facing forward. looks like a pump of some sort... thought that might be a possible location for the starter...

 

[astr]

I was looking through this again, and noticed something, what is on the turbo side of the motor next to the bell housing facing forward. looks like a pump of some sort... thought that might be a possible location for the starter...

That is the power steering pump. It is driven by the same set of gears that drive the overhead cam, oil pump, and injection pump. If you remove the PS pump, it gets you into the timing gear space, not the flywheel space. Although I've never opened it up, I assume that the timing gears are lubricated by engine oil so are sealed from the flywheel. I've attached a photo of the back side of the engine with the flywheel removed. The cover that is circled in red provides access to the PS pump idler gear. The second attachment is from the FSM and shows the whole timing gear train.

It may be possible to somehow to install a starter instead of the pump. It would require quite a bit of additional gear reduction as it appears that the pump turns at about crankshaft speed.

 

[astr]

Vss Mod to T-case adapter

In Post 198, I identified four items that I need to resolve before I begin the final assembly of the A440F/AW450 hybrid transmission. I think I have Item #3 resolved (The AW450 has two vehicle speed sensors, the primary that fits into the speedometer drive hole and drives both the TCM and the electric speedometer and a secondary sensor that only connects to the TCM and is used as a backup if the primary sensor fails. The secondary sensor is a variable reluctance magnetic pickup that triggers from the cogs on the park gear)

I machined a flat on the side of the T-case adapter adjacent to the park gear then drilled it to accept the Vss sensor that was previously mounted on the AW450's tail extension. I also needed to make a spacer to position the sensor with the proper clearance to the park gear.

Photo #1 is of the machined T-case adapter. Photo #2 shows the mounted sensor along with the spacer. Photo #3 is of the inside of the T-case adapter. The sensor tip is circled in red.

 

[astr]

Park Rod Extended

Item #1 is done. I extended the rod that engages the parking pawl inside the transmission by 0.45" I ground the welds off that held the end sleeve to the rod so that I could remove all the pieces from the rod. I added a spacer between the permanent stop on the rod and the spring so that the proper spring tension would be maintained. I next cut a piece of metric tubing to replace the end sleeve that I had buggered up grinding the welds. Everything was reassembled but positioned 0.45' further out on the rod. I then welded the end sleeve back to the rod (weld is inside the sleeve).

The end sleeve is metric tubing 10 mm ID, 14mm OD. The spacer could have been made from the same tubing but I has some 10mm ID, 16mm OD tubing that I used for the spacer.

First pic is a drawing showing the modifications. Second shows the before (bottom) and after (top) of the park rod.

 

[theSherpa]

Well, Andy, I'll be danged! Who knew that AW450 I saw on eBay would have spawned all this? Brilliant reverse-engineering...and fab skills. Carry on!

Steve

 

[astr]

Well, Andy, I'll be danged! Who knew that AW450 I saw on eBay would have spawned all this? Brilliant reverse-engineering...and fab skills. Carry on!

Steve

Yes Steve, you are responsible! You made it sound oh so simple and now look at the fine mess you got me into

 

[crushers]

subsribed.
looks real interesting and i love the hands-on research you are doing.
congrats on having the balls to try this.
cheers

And finally, we have Hybrid A (a little fanfare here – horns a blowing, crowds cheering, etc.) WELL THAT WAS EASY! But will it work? Stay tuned for the next episode “The Great Isuzu-Toyota Merger” or ‘Andy Eats Crow”

The pic is of an A440F transmission with the bell housing and torque converter from the AW450 attached to the front. This combination will bolt directly to the Isuzu 4HE1-TC, no adapters required.

 

[Diverdanshow]

A440F adapter housing

Hello - just joined to take part in this fabulous thread. I have a 95 FJZ80
that needs one of these 4HE1 engines. I am encouraged by your research and
successes. I want to research an idea, to check the dimensions of the adapter
housings of the A440F and the A343F which is in my truck...just in case it may
somehow allow avoiding machining the spacer. My transmission's output shaft
has no threaded portion on the end which is discouraging, but if you could please
measure your adapter housing's length from flange to flange, I'll check mine out
and chime back. Thanks for the stellar tech articles!

 

[Diverdanshow]

Well forget that idea

I got a book and can clearly see that the A343F is way different, the output shaft has no disc attached like the A440F and the extension housing has a totally different bolt pattern.

 

[crushers]

DiverDan,
if your idea works then this gives all the PlayDo owners a new option for the dreaded 2LTE engines.

 

[crushers]

edit:
too bad, i was hoping you were onto something here...

 

[astr]

From what I can tell, the "400" series Aisin transmissions apear to have interchangeable output shafts. What is behind the transmission determines which shaft is used. The AW450 just has and extension housing that the output shaft goes through and is terminated with a yoke that connects to the drive shaft. The A440F drives a split T-case and the A442F drives whatever T-case is used on the 80 series. (I'm not familiar with the 80 serries T-cases).

As you can see from the FSM diagrams for the three transmissions, the front ends of the output shafts appear similar. I've verified that the AW450 and the A440F shafts are interchangeable and assume that the A442F is also. I've never had a A442F output shaft in my hand to actually try.

A question for all you 80 series experts: What years did they use the A442F transmission and behind which engine? What T-case was mated to the A442F?

 

[astr]

Here is a post in the 80 Section comparing bell housing patterns. https://forum.ih8mud.com/80-series-tech/344451-a440f-vs-a343f-bolt-pattern.html Clearly, the A343 transmission body is different than the A440F and the A442F. What is surprising is that the A442F bellhousing is closer to the AW450 than is the A440F. They both have the additional two alignment pins which are missing from the A440F.

 

[astr]

FJ62 Tach Works!

Earlier in this thread, I had a tentative solution for connecting an FJ62 tach to the 4HE1 using an abs sensor. Got it to work just fine and here is a link to the thread:https://forum.ih8mud.com/diesel-tech-24-volts-systems/337036-adapting-oem-tach-diesel.html

 

[MadTripper]

A question for all you 80 series experts: What years did they use the A442F transmission and behind which engine? What T-case was mated to the A442F?

I'm no expert however the A343F is '95-'97, A442F '93-'94, A440F '88 - '92. There are some exceptions however this covers US gassers. I believe the txfer case behind the 442's would be H2FA.

Tripper

 

[Tapage]

I'm no expert however the A343F is '95-'97, A442F '93-'94, A440F '88 - '92. There are some exceptions however this covers US gassers. I believe the txfer case behind the 442's would be H2FA.

Tripper

here you can find the A442 behind 1HD-T and 1HZ engines, 80 and 100 series cruisers, with the part time HF1A or the full time HF2A ( or VC HF2AV ) t-cases ..