Builds Isuzu 4HE1TC into FJ62

[z_power]

Maybe this weekend, I'll fire up the ole chainsaw and try slicing off a section. I just need to find a volunteer to hold the tailhousing while I operate the saw!

How about using stack of 20 gaskets as a spacer? No risk of "weekend-with-chainsaw injuries"...

OK, seriously - if you need to check some interchangeability issues between Isuzu, Toyota and Aisin parts then I'm offering some help in catalogs research.
Mike

 

[astr]

How about using stack of 20 gaskets as a spacer? No risk of "weekend-with-chainsaw injuries"...

OK, seriously - if you need to check some interchangeability issues between Isuzu, Toyota and Aisin parts then I'm offering some help in catalogs research.
Mike

I like the 20 gasket idea especially since I couldn't get the chainsaw started I had to resort to a band saw. Worked OK, but I cut it a bit thick to err on the safe side. The second pic is of the raw slice with the gasket sitting on it. Its going to take me a while to get it milled because I'll be treading in unknown territory (the mill setup) but it should be interesting,

Your offer of doing parts research is much appreciated. I've had no luck extarcting any useful information from Isuzu. I think they wish we would just go away. What resources do you have access to for the research?

 

[Bush65]

I was doing some reading and wondering about how the 4HE1TC shuts down? In the parts list I saw that there was a "Shutdown Motor" which I'm assuming moves a mechanical linkage that blocks fuel flow in the injection pump when activated? I had no idea about diesel motors being able to "run away" from you if you had a fully mechanical fuel system, so wondering how these motors were shut down.

That being said, how is the fuel system set up on the Isuzu NPR? I'm assuming a small lift pump in the tank and then the IP does the rest?

-Phil

Diesel engines are shut down by stopping the fuel. As astr said, the Bosch type inline injection pump, has a cable operated stop lever to interrupt the fuel.

Run away is a different issue and not confined to mechanical injection pumps. It generally occurrs because the engine is getting fuel from some other source than the fuel injection pump. This fuel could be engine oil, from worn piston rings, leaking turbo seals or when a vehicle rolls. Or it could be vapour in the atmosphere, which sometimes occurs on industrial sites.

The fuel stop lever on the injection pump will not normally stop an engine that runs away. In this case you have to block off the air supply to stop the engine - devices for this are mandatory in some industries (such as oil fields) where there may be fuel vapour in the atmosphere.

Sometimes people adjust the injection pump to the point where the governor becomes unstable and can loose control, leading to run away.

 

[AppleTech]

That was a very informative post and explains the difference between shut down issues and run away. Thanks!

-Phil

 

[euclid]

Amazing detail in your writeup. Work and life keeps me from memorizing every detail you have written like I prefer to do before I post.

If it hasn't been mentioned I'd like to bring up the factory weakness of the transmission output gear mating to the transfer input gear on the a440/split case setup. The off the shelf solution is the MacNamerra gear which mates the splines over the entirety of the 2.5 (+/-) length of the output shaft in place of the input gear/spacer/pto gear setup. Welding the gears to the spacer is another solution. I would think this will be key with the increased torque of the Isuzu.

Thanks again for sharing. Can't wait to see the story unfold!

 

[astr]

Amazing detail in your writeup. Work and life keeps me from memorizing every detail you have written like I prefer to do before I post.

If it hasn't been mentioned I'd like to bring up the factory weakness of the transmission output gear mating to the transfer input gear on the a440/split case setup. The off the shelf solution is the MacNamerra gear which mates the splines over the entirety of the 2.5 (+/-) length of the output shaft in place of the input gear/spacer/pto gear setup. Welding the gears to the spacer is another solution. I would think this will be key with the increased torque of the Isuzu.

Thanks again for sharing. Can't wait to see the story unfold!

There is a little wear on the splines of the A440F output shaft that I'm trying to install in the AW450. I've been thinking about going the McNamera route and have been following this thread https://forum.ih8mud.com/60-series-wagons/284711-atf-getting-into-transfer-what-do-2.html to see how RockDoc's install turns out before ordering the gear. I'm concerned about any addition gear noise or whine as a result of installing this gear. Maybe I shouldn't as I suspect the extra diesel noise will mask it.

 

[euclid]

There is a little wear on the splines of the A440F output shaft that I'm trying to install in the AW450. I've been thinking about going the McNamera route and have been following this thread https://forum.ih8mud.com/60-series-wagons/284711-atf-getting-into-transfer-what-do-2.html to see how RockDoc's install turns out before ordering the gear. I'm concerned about any addition gear noise or whine as a result of installing this gear. Maybe I shouldn't as I suspect the extra diesel noise will mask it.

5+ years with McNamera on a new output gear (rodney rebuilt). No additional noise from then till now. Still no gear change clunk.

 

[astr]

5+ years with McNamera on a new output gear (rodney rebuilt). No additional noise from then till now. Still no gear change clunk.

Good to know - thanks for the info. I think I will bite the bullet and order the McNamera gear so as to avoid having to go back into the T-case hopefully for a while. I still have to order a T-case rebuild kit so that when I'm finished, all have an all new drive train behind the engine. I only hope that I can get it to work in my FJ62. If not, I can always stick it back in the NPR and hang a 4x4 front axle under it and end up with probably the only 4x4 Isuzu NPR is the US.

 

[me_tu05]

If you have a tig welder just weld the gears to the spacer, I did and have not had any problems with it.

 

[astr]

If you have a tig welder just weld the gears to the spacer, I did and have not had any problems with it.

That's an idea! How many miles have you put on it since you did the welding?

 

[Moby]

5+ years with McNamera on a new output gear (rodney rebuilt). No additional noise from then till now. Still no gear change clunk.

I'm running about 4+ years on mine without any issues as well.

 

[me_tu05]

That's an idea! How many miles have you put on it since you did the welding?

Maybe a thousand or so, but I have also been wheeling a couple of times since then. It has worked good for me so far, the only clunk I get is from the trans mount being broken.
If you have another PTO gear, you can cut it down to a spacer and use that welded to the input gear. I would have gone this route but I couldn't find an extra gear out here.
I like this build, its hard to find frito trucks and toyota diesels here, keep up the good work!!!

 

[RockDoc]

There is a little wear on the splines of the A440F output shaft that I'm trying to install in the AW450. I've been thinking about going the McNamera route and have been following this thread https://forum.ih8mud.com/60-series-wagons/284711-atf-getting-into-transfer-what-do-2.html to see how RockDoc's install turns out before ordering the gear. I'm concerned about any addition gear noise or whine as a result of installing this gear. Maybe I shouldn't as I suspect the extra diesel noise will mask it.

FWIW, I finally have all the pieces I need to tackle the rebuild. If the weather gets nice by the weekend, I may do it then. I'm looking forward to the Extreme VB + McNamara combo, the lock up in 3rd beats the piss out of things with shifts between 3rd and OD above 80km/h (when the convertor is locked).

 

[astr]

FWIW, I finally have all the pieces I need to tackle the rebuild. If the weather gets nice by the weekend, I may do it then. I'm looking forward to the Extreme VB + McNamara combo, the lock up in 3rd beats the piss out of things with shifts between 3rd and OD above 80km/h (when the convertor is locked).

I'm surprised that the converter doesn't unlock during the 3rd to OD shift. I would have expected that it would. When I get AW450-based transmission together, I'll look closely at how and when the converter lockup work. IIRC, it remains unlocked during the shifts. Probably more important on the AW450 as it locks up in 2nd, 3rd, and OD.

These transmissions also have accumulators that should serve to soften the shifts. You can modify the harshness of the shifts by changing the accumulator spring.

I'll be interested in your thoughts when you get the McNamera gear in. Others, who have installed it, report no additional noise.

 

[Kief]

I have also heard that the pinion flange/hub is the same pattern as the tranny output shaft- have a machine shop or if you have a lathe- match the spacer and then weld it on, cheap version of the McNamara..

 

[astr]

I have also heard that the pinion flange/hub is the same pattern as the tranny output shaft- have a machine shop or if you have a lathe- match the spacer and then weld it on, cheap version of the McNamara..

I see that RockDoc got his McNamera gear installed and has no new sounds. I think I will go that route. It may be more expensive but I got enough other issues that I need to focus on if I want to get this project done.

Actually, I'm surprised that the worn output shaft splines seem to be only a problem with the automatic trannys. Isn't the gear the same on the H42's? If so, it seems like that output shaft would wear the same. Maybe the A440F shaft is not hardened properly.

Any ideas why this is not a problem with the manual transmissions?

 

[Granite Grinder]

I think a few have had problems with 5 speeds as well. I know that one of our club members, Glenn_bj74 put a McNamera gear in due to some slop in the t/c. He reports that it has helped a lot.
Phil

 

[AppleTech]

The lack of updates is disheartening!

 

[astr]

The lack of updates is disheartening!

I feel the same way but I've made some behind the scenes progress. I had to modify a shell mill holder to make it work with my mill so that I could mill the spacer that will go between the T-case adapter and the transmission to the final dimmension. While I was at it, I modified a couple of collet holders to fit my mill also. Slow and tedious work but done!

I also tested a simple approach to making my FJ62 tach work with the 4HE1. I took an ABS sensor (magnet and coil type), hooked it up to the FJ62 tach, and then positioned it next to a steel disk with three notches in it, I used a drill press to spin the disk. Worked like a charm! I checked the reading against an optical tachomenter and it was right on.

The 4HE1 has a hole adjacent to the flywheel for a sensor. My plan is to drill three evenly-spaced holes in the periphery of the flywheel and then install the ABS sensor in the sensor hole. If all works out, I should be able to use the OE FJ62 tach AND wiring.

And finally, I ordered the McNamara gear. I just got an email from Jeff that it is on the way!

 

[AppleTech]

I also tested a simple approach to making my FJ62 tach work with the 4HE1. I took an ABS sensor (magnet and coil type), hooked it up to the FJ62 tach, and then positioned it next to a steel disk with three notches in it, I used a drill press to spin the disk. Worked like a charm! I checked the reading against an optical tachomenter and it was right on.

The 4HE1 has a hole adjacent to the flywheel for a sensor. My plan is to drill three evenly-spaced holes in the periphery of the flywheel and then install the ABS sensor in the sensor hole. If all works out, I should be able to use the OE FJ62 tach AND wiring.

How does the Isuzu normally send tach signal? Is there an issue with the type of signal that it sends so it wouldn't work with the std wiring and tach?

-Phil