Builds Isuzu 4HE1TC into FJ62 (3 Viewers)

[astr]

Next, install two extended dowel pins that replace the shorter stock pins (Photo 1). They are 30 mm long and 12 mm in diameter. I obtained mine from McMaster Carr. Next, goes a gasket followed by the custom spacer followed by another gasket. As only one gasket was supplied with the transmission overhaul kit, I had to order a second one from Toyota.

Finally, slide the T-case adapter on, making sure that the end of the parking lock rod passes between the guide and the park lock pawl. Bolt the T-case adapter to the transmission case with the 10 bolts torqued to 27 ft-lbs. Note that you will need to mix and match bolts from both the AW450 and the A440F as the original bolts from the A440F will be too short with the spacer sandwiched between the T-case adapter and the transmission case.

 

[astr]

Now install the VSS into the T-case adapter. This required modifying the T-case adapter to accept the VSS (See Post #207 https://forum.ih8mud.com/diesel-tech-24-volts-systems/268941-isuzu-4he1tc-into-fj62-11.html. Thread the two studs into the case with a little RTV to seal the threads (Photo 1). Make sure that there is an O-ring in the groove machined into the spacer to seal the spacer to the T-case adapter. Install a new O-ring on the VSS and lube iand the inside bore of the spacer. Slide the spacer and VSS over the studs and tighten the nuts to 69 in-lbs (Photo 2).

All that remains is to assemble the T-case and install the torque converter and bell housing. I’m beginning to see a light at the end of the tunnel!

 

[Nexxussian]

Wow, I finally got to read all the way through.

That's amazing detail and invaluable insight.

Thank you.

 

[astr]

Wow, I finally got to read all the way through.

That's amazing detail and invaluable insight.

Thank you.

You are welcome. The real question is: Did it fix your insomnia?

 

[Pacer]

astr-
Thank you for your incredible attention to detail!
You are clearly meticulous with not only your work, but your writing/photography as well and we thank you for it.
I think many of us are stoked to see how you tackle the starter issue, I'm sure it will be graceful.... and also appreciate bringing this engine to the table as a viable swap; it's quiet, compact and strong. Other than a $printer driveline I see no better option on the road today for our trucks.
One for the books for sure, please keep it up.

Cheers

 

[Nexxussian]

You are welcome. The real question is: Did it fix your insomnia?

I took it in about 3 pieces.

I was looking with an emphasis on what I might do to a JR403E Jatco for reinforcement.

Completely different box I know, but IIRC the FSM lists O rings into the center support like these have, so there's something useful.

 

[Kief]

I feel like I should go make my Mom an ashtray out of Play-Doh or something like that where I can use my special creative skills......


Wow... this is pretty awesome stuff.

 

[astr]

Almost there!

Got the T-case assembled. Unfortunately, the all-inclusive T-case rebuild kits aren't all-inclusive. The bearing that goes into the front of the T-case on the transmission output shaft and the two split roller bearings that the high and low gears ride on on the rear output shaft were not included as well as not all the seals and gaskets for the vacuum actuator that engages 4wd. I ended up ordering these parts from my local Toyota stealership and reusing some of these items which did not particularly please me.

When I ordered the kit for an FJ62, I was assured that all the bearings were included. When I found these items missing, I called the vendor who was sympathetic but his response was far from satisfactory. I was told that the bearing that fits into the front of the T-case housing was considered "part of the transmission" BULL! Also was told that the two split bearings were only used on very few T-cases and rarely needed to be replaced. Well my t-case used them and from reading other posts here it seems quite a few other people's t-case also use them. As far as "don't need to be replaced" - well probably most of the bearing didn't need to be replaced but I'd rather not take the chance. My gripe is that I didn't know up front what I was getting. I ordered the kit way in advance so I would have everything on hand when the time came to do the T-case. End of rant!

1st photo is of the T-case gears, including the McNammara gear. Everything lines up great. 2nd photo is of the complete hybrid transmission with T-case. This is the Isuzu AW450 transmission with the output shaft from the LC A440F and the standard FJ62 split T-case.

Next step is to add some of the misc. items like the rear mount and the high/low shifter and drop it back into the NPR truck to see if it works ???????? (I'm not ready to hang the "Mission Accomplished" banner yet!)

 

[151fab]

That is BS. When I bought my t-case rebuild kit it had extra parts left over because it came with parts for all the variables. Sorry to hear about your experience with that vendor, you should save others from the same problem by mentioning who your supplier was.

By the way, gorgeous build thread, amazing work.

 

[astr]

In retrospect, the T-case kit was probably intended originally for the manual transmission of the FJ60. They threw in a few extra gaskets and deemed it good for the automatic. I did have some extra parts left over - those that would apply to the manual transmission version.

I intentionally did not post the name of the supplier as I don't believe that they were deliberately trying to misrepresent the kit. It is probably the same kit that they all sell. I just wish that I knew what else I had to order up front, not when I'm trying to put the T-case back together.

 

[AppleTech]

Since you are using a 62 case, it's vaccuum operated, yes? Is that just for 4WD actuation or does it control h/l too?

 

[astr]

Since you are using a 62 case, it's vaccuum operated, yes? Is that just for 4WD actuation or does it control h/l too?

The vacuum only engages the front drive shaft for 4wd. H/N/L are manually operated, however, there is an electrical interlock (easily disabled) that when you select Low, it also forces 4wd. If you want 2-Low, all you have to do is disconnect wire from the switch on the T-case that senses Low.

 

[astr]

It's Alive! (sort of)

Finally got the hybrid transmission in the NPR test bed. Took a while to get everything hooked up. Filled the transmission up with atf and T-case with 90W and fired it up. NO GO! Oops, forgot to reinstall the TCM. That would help a lot. Cycle it through the gears, check fluid level and add some more atf. Finally got the atf to the right level. It seems to go forward and reverse. It seems to shift through the gears OK. I got the speedometer up to 60 mph so it is looking good. I'm doing all of these preliminary test with the rear axle on jack stands.

I'm getting a Transmission Check Light and it throw a huge number of codes. These codes could be left over from the time that I ran the truck with the A440F transmission. I need to clear the codes and try again.

I know that I need to adjust the shift cable and fix the lockout switch. The lockout switch, in addition to disabling the starter except in P and N, tells the TCM what gear you have selected. It also lights up the corresponding light on the instrument panel. Only some of the indicators light up so I either have bad bulbs or the switch is malfunctioning. If the switch is malfunctioning, it will be sending bad information to the TCM regarding what gear I've selected.

Overall, I'm pleased with this weekend's progress.

1st photo is the tranny & T-case ready to drop in. 2nd photo is with everything all hooked up.

 

[Granite Grinder]

Very exciting! Nothing like yielding the fruits of your labour, can't wait until you drop the rear end on the ground

 

[ducatiman81211]

Nice!

Glad to see it's coming along!

 

[astr]

... can't wait until you drop the rear end on the ground

I was kinda concerned that this might happen prematurely - the jack stands aren't that robust :whoops:. At least there is a concrete wall a foot away to limit forward motion

 

[mudmud]

Hi astr!

I can't say anymore than what everyone else says! Wow, what a great build! And it looks like I couldn't have come at a better time as you just got it up and running again! I read all through your last 10 months and really like your selection!

I started a thread for my own build at: https://forum.ih8mud.com/diesel-tec...6441-fj40-isuzu-4-9-automatic-conversion.html and I will be asking questions, hope that's ok!!

Here's my 1st!

What is the over all measure from front of engine to rear tail? I'd like to get an idea of overall length as I'm wanting to do this to a 1976 FJ40....

Thanks!

Carl

 

[astr]

Just a quick update. Got the TCM codes cleared. The literal translation of the FSM from Japanese to English had me a little puzzled but finally found the right combination and got the codes cleared. Everything seems to be running fine, althoiugh every once in a while a get a code indicating one of the solenoids is open or shorted. Probably a loose connection. Worse case, I'll have to pull the pan and swap the offending solenoid. No big deal if you don't mind ATF dripping on your face!

I'm still running it with the rear up on jack stands but I'm getting braver - got it up to 80 mph and all appears well.

Next step will be to hook up some indicator lights to the shifting and lockup solenoids so I can really tell what the TCM is telling the transmission to do.

Just as a point of reference, the tach reads 2,200 rpm at 60 mph, exactly the same as my FJ62. I'll definitely will want to run larger than stock diameter tires or swap in FJ60 gears. IIRC, they are 3.7 or there abouts vs. the 4.10's the the FJ62 uses.

mudmud: I'll measure the length tomorrow. I'm working with the 4HE!, Aisin AW450 and the FJ62 split T-case. Is this the combo that you are contemplating?

 

[ozwallaby]

Keep going asta... great job... there should be a 6 star rating for legendary write ups like this one.....the diff ratios you are speaking of are 3.7:1 (37:10) and 4.11:1 (37:9)... both are standard Toyota ratios... I actually don't know of or even if, there are any other std ratios in other models (earlier or later) though as far as I know these are the only ratios available std in 6x series...

 

[astr]

...what is the over all measure from front of engine to rear tail? I'd like to get an idea of overall length as I'm wanting to do this to a 1976 FJ40....

The 4HE1/AW450/Split T-case combo measures 65" from the plate that the OE fan mounts on to the back of the rear output flange on the T-case.