Marilu Upgrades Ver. 2009

[Tapage]

Well .. Hello all mates .. this will be a semi long thread with plenty of pics .. it's all about upgrades already done to Marilu .. I take 2 off office weeks to do the main job and let another 2 weeks in the body shop for other few things ..

In my sign you can found the previous 2008 Marilu Upgrades ..

Well this start few years agoo when I was looking for a good 80 series .. mostly here in Panamá are A442F so I choose one and ar this right time also start my manual tranny search ...

In the proces ( and time ) I was thinkiing in Rodney A442 extreme valve body .. but that was plenty of money to me and DD down time ..

Along with this process .. I upgrade to 315 Toyos ( more than happy with those tires ) and decide I will use an H150 tranny .. those that come in the 1HZ 80 and 70 series .. with shorter shifter ration on 1st, 2nd and 3rd .. to help with my 315.

Big long procees searching for all parts .. ( I wasn't in a hurry anycase )

Usually the HDJ80 ( like mine ) with the 1HD-T engine comes with H151 tranny .. that have longer ratios it's the same tranny that come in the manual FZJ80 with the 1FZ-FE engine ...

the problem comes with the tranny input shaft ..

the H150 use a 21 fine splines input shaft along with a 275mm clutch .. and the H151 use a coarse 14 splines ( weird but true ) and 300mm clutch ..

Here the comparision of clutch sets ..

One of my goals was use a 300mm clutch ( disc and Pressure plate ) ..

My shifter

I was a lucky guy and after month and month got an H150 tranny .. complete !

Thanks Tito .. !

 

[Tapage]

Well after my tranny score .. still have a bunch of things to solve .. my 80 it's my DD .. so factory clean look was a must ..

After the tranny itself .. start witht he clutch assembly parts .. I got 2 options .. go the factory route and use the 275mm clutch or make a nice upgrade to a 300mm clutch ..

Searching on the web, found few parts# from Isuzu for a 300mm disk 21 fine splines .. and I went to the local Izusu dealer at least 10 times ..

Here my flywheel .. ( got both 275mm and 300mm ) 300mm

The PPlate was easy .. extreme easy, coz it's a factory sotck 300mm PP for a 1HD-T both flywheels ( 275 and 300 ) are same size overall .. the only diference are the disc mirror ..

And no you can't use a 300mm flywheel and PP with a 275mm disc .. it let you only with less than 60% of contact surface ..

Anycase ... with patient ( big patient to deal down here with the parts shops and dealers .. how hard to explain that I know exactly what I'm doing .. )

nice view ..

1HD-T 300mm PP

 

[Tapage]

The Isuzu disc it's pretty thick !

the hole thing ..

Here is the magic .. I hope it helps for future reference .. it cost me about 182 bucks or so ..

My PP it cost me around 140 bucks

It take me time to found all stuff .. bearings, pedals ( all 80 series stuff .. complete bolt on ! ) and when I was ready with all things .. the real job starts ..

really need a good sheet metal cut ..

need to admid with 4 good arms still a hard job .. that A442 it's F***ing heavy !

 

[Tapage]

A442F flex plate and starter out ..

my big mess of cables for my 4 gauges ..

this pic make my day .. nice and easy 300mm clutch

area to be cut ..

Another part of the job was removing all auto tranny lines that I don't gonna need anymore .. and re route the front tranny cooler lines to be used by my PS pump ..

In the middle of .. take time to clean my dust air filter can ..

back to the main job .. 300mm clutch installed ..

 

[Tapage]

with no tranny on Marilu take some pics of the AC lines that goes to my factory center console fridge ..

more lines ..

other ones that goes to my rear AC

back to the main job again .. time to work on clutch master .. there is the factory hole ( comes with a gromet and I was using to get all my cables in .. ( no more that easy way )

now this it's my PS cooler ..

those factory bolt was waiting for the pedal assembly ...

it fit perfect and here you see the other attachment point ( 8mm bolt IIRC ) PITA make it fit !

 

[Tapage]

Along with my tranny job another upgrade was moving .. I was alwais wondering why nobody make a 2 section rear bumper .. using the stock factory end of the frame in 80 series .. ( now I know the answer ) I want one ..

1/4 plate .. and

Also wanna keep my rear mudflaps ..

 

[Tapage]

Well back on my tranny .. BIG PITA !!!! bolt the manual tranny back .. ( without t-case off course ! ) we need to make some more space on the tranny tunel .. and still big PITA !

I didn't take much pics of this process .. ( was busy with the PITA and dirty job ! )

But here is the partial result ..

I said partial coz I order from Toyota this manual shifter console ( new model ) for my swap .. to make it all fits as factory .. and keep as clean as I can the swap job ..

Big surprise when I note that due to the new dash the long of the console are diferents .. so I need to go back and order a new one ( old model ) that fit perfect ..

Here a comparision .. 58811-60030-03

Here both old models .. manual and auto

both manuals, old and new model ..

I can make the new model function but don't want .. ( more due to my guages and pod )

 

[Tapage]

well .. that was in the middle of the night and in the middle of the main job .. back in the garage was time to make my clutch master fit ..

hard line and flex line .. as factory as posible ..

now I'm using my tranny temp gauge for my oil engine temp ..

pedals .. big thanks John for that .. !

 

[Tapage]

Ajá ! here another big PITA part of the swap .. the crossmember ..

Before I start the job I was sure that my frame got the holes for the manual tranny .. ( that BTW it's shorter than a A442 in around 3" ) but I never check for the nuts inside ..

I go to my wife 80 ( Autana from Venezuela ) and her damn frame have the holes and the nuts welded inside ! ( her are factory manual .. so the frame it's ready to accept the auto tranny and crossmember )

So we need to be creative .. we do as best as we can using the holes and welding nuts then make a plate to use the inner hanger holes ... a pic can talk better than my english is ..

a teaser from my rear bumper ..

 

[Tapage]

with the tranny up and working .. I decide was time to make a little improvement, when I got the 3" exhaust ( 2008 upgrades ) was just a 3" pipe .. bubt since the diesel engine god much more vibrations than a gasser .. I was thinking in a flex pipe ..and finally order it and install it ..

it make my exhaust little less noiser .. now you can't ear as free as it was the turbo .. but no big deal anycase .. I promise a vid soon ..

I didn't take pic of my DS .. but the rear must be longer ( in about 3" ) and the front must be shortened in about the same .. ( due to the new tranny lenght )

 

[Tapage]

At the end of the job .. I make a cover and modify the stock auto tranny base ( not sure how to name it ) to support the manual shofter console ..

the happy ending .. !

Ajá .. another big PITA in the process .. the way that the A442F sends the reverse signal to the harness .. the H150 make a ground .. and then spend big time looking in to the wirring diragrams ( the max ellerys help a bit ) to know where it was in the A442 ..

After one complete night looking into, got the signal from the auto A442 shifter selector, but need to make another circuit to make it function .. with a proper relay ( 87 and 87a ) make a nice thing ..

when I'm in reverse .. off course it only will function with the ing ON

another issue was the tacho ..

when I remove the tranny .. I remove everthing ! ( and I was happy ! ) but when the H150 was in and ready to start the engine .. need to mess with 2 things .. ( another ! )

1. the neutral safety switch .. that after locate it .. easy solved with a proper bypass .. !

2. there was no tach !!!!!!

I was feeeling dead with no tach ( I was thinking in a aftermarket tach etc .. ) but again big waste of time looking in the wirring diagrams let me know, that from the IP and the tach sender ( inner part of my 1HD-T IP between IP and block ) the signal goes to the transmision relay and the ETC and then to the dash ..

So after all was a easy solution .. just reconect the transmision relay and the ETC computed .. then I got my dash tach function again !

here how it looks now .. !

all fits just perfect ..

 

[Tapage]

The ultimate upgrade for this year it's this BIG score that I made in a Toyota Factory Electric Winch !

here is the 80 series winch ..

the one that I source was from a 105 series .. ( it's slightly bigger )

so along with my rear bumper .. come a front bumper mod ( was no more money for a new front bumper .. )

 

[Tapage]

the winch come with the 105 base plate .. but it won't function in 80 series setup .. thought due to the 100 series body it's bigger, with much more behing bumper room and higer body over the fram .. so few mood was in it ..

this winch with a bigger gearbox take ground throught the winch body .. what make the wirring much more simple ..

just one conectot to my batt

the front winch plate ..

side winch view

well then here is my reear bumper ..

 

[e9999]

very impressive, it would take me a year to do that trans swap if I could do it at all....



(and you had a perfectly good auto trans to start with....? )

 

[Tapage]

Here is how she looks today ..

yes I know .. I need a new front bumper .. but I'm under the impresion that it don't gonna happend this year ..

Some conclusions about my proyect ( or proyects .. )

1. Manual tranny = lower temps ..

- With everything as same as it should be .. I got from 60° to 100°F drop in EGT, no need to said, that means colder AC and from 6 to 8 more PSI ( oil press ) thought due to colder engine thicker oil ..

2. Responsive

- I feel a much more sensible gas pedal .. for good or bad, the engine can spin faster and easier .. I can rev up in 1st and ear my tires screan in 2nd ( just a few test )

3. Top speed .. I didn't have much time to test it .. but in a short run, I can reach easy 150 - 160km/ with 3,000 rpm aprox ... ( 140 km/h in my dash )

4. Time frame ..

- Iff you have all parts bolts, and tools thought I can do the tranny swap in a 3 - 4 days .. but here in Panamá to me was a month proyect ( 2 weeks on the tranny swap and another 2 weeks for everithing else )

Big thanks to all my great mates and persons that help and make it posible ..

Tito / John / Julio / Carlos / Carlitos / Eric / Mr. Alvaro / Molina / my Lovely Wife and sure Me

 

[e9999]

it's beautiful, but Dude! a month of top notch work and you got a droopy hood emblem? I don't think that's gonna help you with the ladies...!

 

[retrofive]

NICE Job and beautiful truck!

 

[Tapage]

it's beautiful, but Dude! a month of top notch work and you got a droopy hood emblem? I don't think that's gonna help you with the ladies...!

Actually my wife didn't notice .. but It was a mistake when I was polishing she ... I need to take time to work in the emblem spring .. or remove it .. ( didn't like it that much )

 

[Dusty]

wow.

great work. thats the most tech in the 80 section in a long time

hope you will be driving to cali some time in the future. if you come by and let me see your truck you can stay a couple days and wheel that thing with me.

 

[MoJ]

very nice! I've always hoped someone would fab replacement wings for the rear bumper. Congrats on finishing a big project.