Builds LX450 "Rex" Build (1 Viewer)

[NeverFinis]

Checking DeltaVS bumper fitment... I will have to pull it off to do some simple body work.

Prepping tailgate for storage...measuring more than twice...

Rust flakes inside frame...

Don't tell my wife, but the dryer vent tool works great at taking rust out...

 

[NeverFinis]

Tailgate cut open. Very clean inside. After the fact, I noticed that the holes in the Big Country Tailgate Storage Lid lines are perfectly with the holes meant for the original panel. Nice. I wish I knew that before because it would have made it a ton easier lining up everything and figuring out where to cut. Instructions don't make mention of using the holes for alignment, just align the lid to the tailgate by using the rear edge of the tailgate as a measurement point.

I noticed a slight bit of surface rust at the bottom lip of the tailgate.
That is the external plastic cladding that is just above, which means it needs to be removed. I probably should take care of it before I put carpeting inside the tailgate. I just have to figure out those clips..

This is a mystery. These are the internal nuts for the license plate. That is a plastic bolt that is partially drilled out to make way for another fastener. The other license plate bolt is like this as well. I thought the bolts were steel at first....I drilled them out and tapped the threads, but plastic bolts?

 

[NeverFinis]

I finally pulled the trigger. I just bought an 2020 L96 + 6l90e with 26K miles. I was going back and forth between a L96 or a L83. Fuel Efficiency, Reliability, Direct Injection, Port Injection, Weight...

Some pictures from the last few days.

When installing the rear DeltaVS bumper, I snapped a bolt, but had an almost equal replacement on hand. A fully galvanized version. Instructions said to torque to 37 ft-lbs and it didn't make it.

The latest instructions found on the web doesn't mention anything about torquing that bolt. I was much more careful on the other side and didn't go to 37 ft-lbs.

I redid the cross bar, which is behind the normal bumper. I figured out how to do electrolysis to remove all the rust. It took a week sitting in the bath, and then painted it. Didn't need it. DeltaVS replaces it with their own...

These tailgate stays were all bent. Not anymore. They still appear to be available from Toyota.

These hinges were extremely stiff. I worked them over with PB Blaster.

This bolt didn't hold the 96.6 ft-lbs. It was one of the ones that I had to drill out, but I accidently re-tapped it with M10x1.5, forgetting that it should have been M10x1.25. I have a Heli Coil on the way. I am not sure it is needed since it is only holding on plate, but it could be tying the bumper into the frame.

 

[NeverFinis]

Rear bumper done. The right swing arm will eventually hold a storage/kitchen box. I will be focusing on the fuel tanks next, and then the engine swap.

 

[NeverFinis]

Just to add, when the tail gate is down, there is one bolt that is very close to the LX450 trim on the tailgate when it is in the down position.

DeltaVS does provide shims to move the bumper down for extra tailgate clearance. What I might do is switch the bolts out to low profile button heads instead.

 

[NeverFinis]

I ran into a problem. Snapped both bolts that hold the gas fill tube to the underside of the body. Usually not a problem but a frame crossmember blocks access to these bolts from below.

My options appear to be:
I can cut small access holes from the top and drill out the bolts. I would weld the floor pan closed.

or

I can cut small access holes from the side and Dremel out the nuts, and use new nuts. I might leave rubber grommets in place.

or

I can lift the body above the frame about 4" and drill out the bolts from below.

I will be swapping out the motor, so the last option isn't as crazy as it seems..

I am dropping the gas tank at the moment.

This is what a gas tank looks like after 25+ years and sitting for the last 8 or so...I do have a replacement tank.

This is what the fuel pump and sender looks like. I am hoping to replace it with the diesel version as I have heard it has a bigger outlet. I need to locate the part number.

 

[NeverFinis]

My new sway bar links arrived! Wow, mine were bad! Thanks @landtank

Goal is to have every thing associated with the drivetrain as new as possible.

 

[NeverFinis]

well, this arrived unexpectedly.. 7 days after buying on ebay, truck just backs into my driveway to drop this off today. 2020 L96 + 6l90e

I worked on installing the dual filler today. I had to cut short the vent tubes due to interference with the body. I need to find 1/2 ID fuel hose that starts with a 90 degree bend. My finger is pointing to where I think I need to add a second support. It does attach to the body at the back, see the bolt at the bottom of the picture.

New vs Old

 

[NeverFinis]

I haven't posted much lately, vacation..other projects...limited weekends. I am currently tearing the engine bay apart...that wiring harness...what the hell. I now have a few tricks thanks to Mud.

The new Fuel Sender arrived from ISSPRO for the LRA tank. Part number can be seen in the photo. The one originally sent from LRA appears to be a Toyota aux sender with an inappropriate resistance range, E 155 ohms to 0 ohms F. The fuel gauge they sent me needed E 0 to 90 Ohms F, which was a GM standard. I even contacted the designer of the fuel gauge to confirm. He quickly responded despite being out the business for years. Much appreciated. The Toyota sender was also way too small as well, as you can see by the picture. It would appear to show empty despite the tank being 2/3 full.

The ISSPro gauge works well with square tanks due to its vertical design, E85 rated and fits in the hole, which is an industry standard opening for fuel senders. Next step is to clean/paint the frame in the area where the tank is going and just install the thing...lol. Although I am now prioritizing the engine swap over everything else. I need to disassemble the 6l90e to remove the output shaft for machining.

I really enjoy this stuff.. for real...

 

[lelandEOD]

Cool build. Where’d you source the dial filler neck assembly from?

 

[NeverFinis]

Cool build. Where’d you source the dial filler neck assembly from?

Thanks. The dual filler neck came with the Long Range America tank originally, which is sourced from Australia. The fuel filler probably didn't come from an 80 series since the vent tubes don't fit and I need to modify them.

 

[NeverFinis]

I needed to remove the 6L90 output shaft to get it re-splined from 36 to 32. I have never torn into a transmission before. It wasn't that complicated...I hope it goes together as well as it came apart.

It wasn't as bad as I feared, but the massive snap ring was a problem. I think I should have gone with the high dollar snap ring pliers meant for the snap ring, but I went with the $60 Amazon special that I had to modify. They worked, but not without swearing.

Finally, here is the output shaft next to the Marks 4WD Spud Shaft

I have reached out to Moser Engineering about re-splining it.

 

[NeverFinis]

My crude drawing on how much I need to trim the 6L90 2WD output shaft. Mark's 4WD says to shorten the output shaft to 95-97mm, measured from the transfer case mating surface.

Everything is inches because my calipers are only in inches. I will have Moser Engineering take off 2.713", chamfer and re-spline to 32. I am hoping I am right ...the output shaft gets shipped to Moser today.

 

[Rusty Marlin]

Wow, that's quite the project!
It's good to see your keeping the enthusiasm up.

 

[NeverFinis]

Resplined 6l90e output shaft just arrived from Moser Engineering. Moser converted it from a larger diameter 36 spline to 32 spline.

It might be a 1 or 2 mm too long. Depending where you measure, I get 97 to 99mm from the transmission's face. Mark's 4WD wants it to be 95 to 97 mm. I rather it be too long than too short.

Here it is assembled into the transmission. You can see the two new plugs and the new 4WD rear seal, which is needed if you start with a 2WD 6l80/90. I bought the plugs from Dorman and rear 4wd output seal, but a transmission seal kit includes both.

This is my first time taking apart a transmission. It was intimidating. The hardest part, other than the snap ring from hell, is getting all the clutches to line up as you put everything back together.

 

[NeverFinis]

I attempted to remove the T-Case from the LX450 last weekend....and failed... It only separates from the transmission fractionally.

I wanted to assemble the new drivetrain to check the new 6l90e output shaft length and compare that to A343F output shaft length. Get actual numbers...

I found this thread here, and noted that the poster used a large lead hammer. I do have a big sledge hammer, but I can't see swinging that thing underneath the truck. One trip to HF, and I picked up way more than I actually needed...including a large short handle sledge hammer.

This just arrived quickly from The Land Cruiser Shop because mine looked crusty. It is designed for a LS/6L80e conversion, and looks like it has plenty of adjustment. A 6l90e is 35mm longer than a 6l80e, but transmission placement depends on where you put the motor.

Engine porn.

I decided to spray fogging oil into the L96 and removed the valve covers to do so. This is what a low miles L96 valve train looks like. The simplicity of this motor is amazing.

 

[Filo Bedo]

I’d love to do the same engine swap, did you get all of the electronics with the engine? ECM, TCM, gas pedal etc.

 

[NeverFinis]

@Filo Bedo I did get all the electronics and wiring with the engine. The engine came with a E78 ECM, and the TCM is inside a 6l80/6l90 transmission. The motor I bought came out of a 2020 GMC Savana van. This means I got a van gas pedal, which isn't ideal but should still work.

 

[NeverFinis]

I took apart the transmission again, just to confirm that everything is seated properly.

I had already put it back on the engine, but after watching more 6l90e videos, and I had more of an idea what to look for when all the clutch packs are seated. I had everything set right.

I also had to put a GM magnet into the transmission pan. The magnet just arrived, as well as a transmission filter. The yard removed the original magnet, and the transmission filter. I assume to make sure a new filter is installed, but I am not sure why they would remove the magnet as well.

I was finally able to remove the transfer case. A BFH was key.

Before separating it from the transmission, I strapped it to my jack with a 2x4 for stabilization. It worked like a charm.

I measured the A343F transmission output shaft and it was ~55mm from the mating surface. I now know how far Marks 4WD spud shaft should extend outside their adapter housing.

I test fitted Mark's 4WD adapter housing to the 6l90e. Wow, it is a tight fit. Almost too tight.

 

[Filo Bedo]

Any new updates? I’m looking forward to a video of it running.