Mitsubishi 4D34-2AT3B diesel swap into 96 FZJ80

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SuperHatch said:
...On a completely different note...

https://www.wittrans.com/showfilter.aspx?Category=1287&Section=174

Brand new A442F Extension Housing for $79

https://www.wittrans.com/showfilter.aspx?Category=1287&Section=118

Brand new A442F Output Shaft for $53
Click to expand...

As Frommage pointed out, they list an output shaft for the A440, not for the A442. They claim the A440 output shaft to be 7.5" long and the AW450 output shaft to be 8" long. If you look here https://forum.ih8mud.com/diesel-tech-24-volts-systems/268941-isuzu-4he1tc-into-fj62-5.html (Post 96) you can see that the A440 output shaft is definitely much longer than the AW450 shaft so something doesn't jive. The photo shows the A440F output shaft out of a FJ62 and an AW450 shaft.

It is possible that the A440 shaft that they are referring to is the one used in the 80 series rather than the 60 series. The 60 shaft would be longer as it passed almost all the way through the T-case whereas the 80 series shaft has a splined stub that only protrudes about 2" past the T-case adapter and mates with a t-case shaft.

If this is true, then there are two different output shafts for the A440F, depending on which T-case is used.
 
Related or not; I dont know because I didnt read the rerast of the posts, but:

A bell housing from an A440F from a HJ61 can be made easily to fit an A442F from HDJ81

This was done recently putting in a 4.35L 12HT into an 80 series.

A442F 1HDT torque converter was also easily made to fit the 12HT flywheel (or whatever they are called)

Easy means; "did it on the fly"
 
Dougal, two issues.

I am not getting anywhere near 275g/kw-h based on the numbers posted. Can you please lay out your logic as well as your numbers, or the conversion formula. I am unfamiliar with BSFC so maybe I made a mistake but it's just a game of unit conversion. I am getting near 225 g/kwh.

Second, I don't think you can go around rating engine models/families on efficiency based on an EPA tag without stating the exact CPL/build number and model year of the engine. There exist in many cases dozens of tunes and available set ups that have a dramatic effect on efficiency. Case in point, the Cummins 4BT has a huge range of timing and advance possibilities, and stating that a 4BT is less efficient than a 4BD1T is misleading. Yes, perhaps in your extremely limited data set, you have proven than one build of the 4BT is less efficient than the Isuzu or the VW diesel, but I would not hang my hat on it. I understand what you are doing, but I think the test pool (especially with the Cummins motors as there is so much variance) is too small.
 
Dougal, two issues.

I am not getting anywhere near 275g/kw-h based on the numbers posted. Can you please lay out your logic as well as your numbers, or the conversion formula. I am unfamiliar with BSFC so maybe I made a mistake but it's just a game of unit conversion. I am getting near 225 g/kwh.

Second, I don't think you can go around rating engine models/families on efficiency based on an EPA tag without stating the exact CPL/build number and model year of the engine. There exist in many cases dozens of tunes and available set ups that have a dramatic effect on efficiency. Case in point, the Cummins 4BT has a huge range of timing and advance possibilities, and stating that a 4BT is less efficient than a 4BD1T is misleading. Yes, perhaps in your extremely limited data set, you have proven than one build of the 4BT is less efficient than the Isuzu or the VW diesel, but I would not hang my hat on it. I understand what you are doing, but I think the test pool (especially with the Cummins motors as there is so much variance) is too small.
 
For BSFC you take the power available in the injected fuel (85 mm^3 per stroke on the EPA tag) and compare that to the power produced (145hp at 2,.900rpm).

In this case we want the numbers in grams per kilowatt hour.
145hp = 108.1kw.
2,900rpm at 2 power strokes per rev = 348,000 power strokes per hour.
85mm^3 per stroke x 348,000 strokes per hour = 29,580 cc of diesel per hour

Diesel has a density of 0.85 kg/litre. Our 29,580cc of diesel weighs 25,143 grams.

BSFC is 25,143 grams of diesel divided by 108.1 kilowatt hours.
= 232 g/kwh.
This is 34% overall efficiency.

God knows where I got 275g/kwh from, I didn't keep that calculation to check. Sorry about that.
 
astr said:
As Frommage pointed out, they list an output shaft for the A440, not for the A442. They claim the A440 output shaft to be 7.5" long and the AW450 output shaft to be 8" long. If you look here https://forum.ih8mud.com/diesel-tech-24-volts-systems/268941-isuzu-4he1tc-into-fj62-5.html (Post 96) you can see that the A440 output shaft is definitely much longer than the AW450 shaft so something doesn't jive. The photo shows the A440F output shaft out of a FJ62 and an AW450 shaft.

It is possible that the A440 shaft that they are referring to is the one used in the 80 series rather than the 60 series. The 60 shaft would be longer as it passed almost all the way through the T-case whereas the 80 series shaft has a splined stub that only protrudes about 2" past the T-case adapter and mates with a t-case shaft.

If this is true, then there are two different output shafts for the A440F, depending on which T-case is used.
Click to expand...

As I said above, I made the mistake of assuming that the FJ80 A440F and FZJ80 A442F shared the same extension housing and output shaft since the transfer cases are interchangeable between the two. I was wrong as evidenced by the Toyota part numbers.

I will take measurements of my A442F extension housing and output shaft after I pull the trans apart this weekend so we can compare to the dimensions on that page.


Even if there are subtle differences, I believe that since all 80 series TC's are interchangeable, we should be able to use the FJ80 A440F parts to accomplish the same goals.
 
Well, I got both of my transmissions apart. The A442F was so clean inside I actually felt bad tearing it down for two stinkin parts... ah well.

FWIW, the A442F output shaft is 8-1/8" long, which matches one of the A440F shafts on this page...
https://www.wittrans.com/showfilter.aspx?Category=1287&Section=118
Conveniently, it's the cheaper one.

Also, the extension housing is 4-5/8" long, which also matches one of the extension housings on this page...
https://www.wittrans.com/showfilter.aspx?Category=1287&Section=174
Also the cheaper one.

Fromage, want to be a guinea pig? I honestly might order them just to be able to put the A442F back together.

The AW450 on the other hand was pretty nasty inside, or as some of my friends would say... "dirty nasty". I will be replacing all of the clutches in the trans when I reassemble, but the steels don't have heat scoring so they're staying put.
 
On to the pictures!!!

A442F with the housings removed, pulling it apart with my makeshift tool, and everything bag'd and tag'd.
2011-08-05_10-30-44_424.webp
2011-08-05_12-20-05_248.webp
2011-08-05_12-20-15_419.webp
 
Looking good!

Since you won't be able to completely drain all of the skunky ATF from the torque converter, once you get the transmission back in the truck and filled with ATF, you may want to leave the return line from the cooler disconnected and let the transmission pump new ATF through the torque converter into a drain bucket until you get clear fluid coming out - a Rodney flush on first startup.
 
astr said:
Looking good!

Since you won't be able to completely drain all of the skunky ATF from the torque converter, once you get the transmission back in the truck and filled with ATF, you may want to leave the return line from the cooler disconnected and let the transmission pump new ATF through the torque converter into a drain bucket until you get clear fluid coming out - a Rodney flush on first startup.
Click to expand...

Sounds like a good idea... I just ordered the rebuild kit with clutches, but no steels. I'm also going to place an Amsoil order. Trans fluid, TC fluid, oil for the diffs, and grease for the birfs and bearings. Not looking forward to that bill, haha!
 
Ordered the following parts from Mr. T. These are all the parts needed to convert my A343F shift linkage to A442F shift linkage:

90170-A0001 - NUT, HEXAGON
94512-00800 - WASHER, SPRING
94612-10800 - WASHER, PLATE
33723-22010 - SWIVEL, CONNECTING R
94613-10800 - WASHER,PLATE
90389-08005 - BUSHING, NO.1
90480-17177 - GROMMET
90468-14017 - CLIP
35569-60030 - ROD, TRANSMISSION CO
90480-17177 - GROMMET
90389-08005 - BUSHING, NO.1

Also ordered the following:

35182-60010 - GASKET, EXTENSION HO
- This is a spare extension housing gasket, since only one will come in my overhaul kit and I will need two (one for each side of my spacer)
32921-60130 - TUBE, OIL COOLER INLET, NO.1
32922-60070 - TUBE, OIL COOLER OUTLET, NO.1
- These are the oil cooler tubes for the A442F, they were cut on my junkyard trans, and I didn't think the Fuso ones would have fit under the floorboard, the LC ones hug the transmission much closer.
36308-60160 - ROD SUB-ASSY, HIGH & LOW SHIFT
- This is the shift rod between the transfer case shift lever and the TC. It was broken on my junkyard transmission.

The total from a local dealer ran $204.79 with free shipping.



I ordered the transmission overhaul gasket kit with clutches from www.wittrans.com. I also ordered a couple spare snap rings. Total was $254.67 shipped.

So this is where I'm at so far...

1999 Fuso Donor - $1800
Towing charge - $425
Pair of Diehard Platinums - $365
Cab Recycling - $122
Chassis Recycling - $310
1st Batch of Misc AL Recycling - $307
Threaded rod, nuts, drill rod from McMaster - $38
Last batch of AL Recycling - $504
Junkyard A442F w/ Shifter and TC - $400 shipped
Shifter Parts from Mr. T - $205
AW450-43LE Overhaul Kit - $255

Running Total - $2245
The only things left to buy to get the engine/trans in the truck are the exhaust gaskets from Mitsu so I can flip the manifold and turbo. Then I'll figure out what I need for exhaust parts, IC pipes, Radiator hoses, fuel lines, P/S hoses, A/C lines, etc. I really think I'm going to come in under $4000 easily, maybe even under $3500. Then I can sell my 1FZFE and A343F to hopefully recoup even more of the costs. If I can walk away from this conversion with less than $3k out of pocket I'll be tickled pink.
 
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