Mitsubishi 4D34-2AT3B diesel swap into 96 FZJ80

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Got the trans back together... I wish I could say it was a 1-2-3 easy as pie operation, but I had my fair share of hicups along the way...

Clutches getting a good Soak before the operation, and the cleaned case with a machines shifter surface and side mount.
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Here is the first hicup I hit. You can see how the trans side of the protrustion on the park lock gear is larger on the A442F than on the AW450. Well if you install the A442F Park Lock Gear into the AW450 trans, that large surface hits the non-rotating portion of the output shaft bearing. The output shaft bearing on the AW450 is different than the A442F. Had I known this, I would have swapped bearings. But at this point the entire trans was together.

In the second picture, you can see how the AW450 park lock gear has a protrusion on the backside that the A442F gear does not.

I put the AW450 park lock gear on the trans, and then measure the length of splines after the gear before the first snap ring groove. I then had the A442F park gear spacer machined don to 0.900" of an inch to take up this space, and then put the snap ring in.
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Got the extension housing installed, only to find out it was spaced too far back for the park lock rod to engage into the park lock actuator. So, I took the housing off and measure the distance. I needed the rod to come back another 0.250".

I stuffed many a rag into the entire tailhousing area and then proceeded to cut the sleeve on the end of the park lock rod between the actual engagement sleeve and the welded end. I was able to split this off, and the spring had enough extension in it to push en egagement sleeve the additional 0.250" down that I needed. Unfortuately I didn't take any pictures of this.

Another thing I learned, the AW450 park lock rod is larger in diameter than the A442F rod. So, it won't engage into the A442F reciever that bolts into the extension housing. The two "fingers" are too close together. Also, that reciever is hardened steel, so don't try to bend them out, they'll just break (Ask how I know)

Also, the reciever on the A442F has a slightly smaller bolt pattern than the reciever from the AW450, so they won't just interchange. You need to elingate the holes... good luck on hardened steel. I ended up using my plasma cutter!!! But hey, it worked, and with those two mods I have park now, which is kinda a big deal to me.

Low and behold, the whole mamma jamma came together, this is one HUGE transmission!!!
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One more pic of this monster...

Now it's time to button up a couple more things on the trans (breathers, rear speedo sensor, TC shifter), and then I'll bolt the trans back to the engine and get ready for the install!

I want to flip the exhaust manifold and get the turbo oil lines worked out first though. If all goes to plan, I'll get the 1FZ out and the 4D34 in
during Labor Day week!
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Quick question - what year did Mitsubishi switch to the Aisin AW450 transmission? I have a friend with a 1992 truck that has the Jatco automatic.
 
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Thanks for he year info.

It looks like you had to make exactly the same mods for the A442F as I did for the A440F: make a spacer to go between the T-case adapter and the back of the transmission case, extend the rod that activates the shift pawl, modify the guide that the park rod fits into to match the different bolt spacing in the T-case adapter, and add a spacer on the output shaft to position the park gear correctly.

I would have guessed that the AW450 was closer to the A442F and so many of these mods would not have been necessary. Good to know.
 
astr said:
Thanks for he year info.

It looks like you had to make exactly the same mods for the A442F as I did for the A440F: make a spacer to go between the T-case adapter and the back of the transmission case, extend the rod that activates the shift pawl, modify the guide that the park rod fits into to match the different bolt spacing in the T-case adapter, and add a spacer on the output shaft to position the park gear correctly.

I would have guessed that the AW450 was closer to the A442F and so many of these mods would not have been necessary. Good to know.
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Pretty much, yes. Some differences are the way the case itself is modded to accept the A442F TC Shifter, and my choice on the Park Gear spacer. If I had used the A442F Park Gear, I wouldn't have needed to modify the A442F spacer to suit. But then I ran into the problem described above with the flange on the A442F park gear being larger than the AW450 and the ensuing interference.

It is intereting to note that some AW450-43LE literature I've found actually refers to the trans as an A443, which is consistent with Toyota's nomenclature.
 
Great work! Why do you want to flip the manifold? Will the turbo not fit well enough mounted low like it is? Don't get me wrong, I like the idea and the look of a high-mount turbo sitting up out the engine bay, I'm just curious.:)
 
Falco80 said:
Great work! Why do you want to flip the manifold? Will the turbo not fit well enough mounted low like it is? Don't get me wrong, I like the idea and the look of a high-mount turbo sitting up out the engine bay, I'm just curious.:)
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Actually, the sole reason for doing it is more clearance between the turbo outlet and the firewall. Flipping the manifold pushes the turbo forward quite a bit.

Take a look at this post...

https://forum.ih8mud.com/diesel-tec...-diesel-swap-into-94-fzj80-2.html#post6515550
 
Rock On!

A few considerations before you plop it in:

Remove the glowplug relays located on the starter. They will hit the floor on the driver's side.

Relocate the fuel filter forward, it will hit the booster. I used a piece of aluminum angle and moved it forward about 4 inches, and re-made the lines.

Remove the steel valve cover cover. There is a nice aluminum underneath. You will need the clearance.

I think the tranny vent will hit the floor. You may want to extend it with some hose.

Did you figure out the coolant elbow?

Looking really good!
 
Fromage said:
Rock On!

A few considerations before you plop it in:

Remove the glowplug relays located on the starter. They will hit the floor on the driver's side.
Click to expand...

I remember reading that from your thread... I'll be sure to put it on my to-do list.

Fromage said:
Relocate the fuel filter forward, it will hit the booster. I used a piece of aluminum angle and moved it forward about 4 inches, and re-made the lines.
Click to expand...

I need to figure something creative out for this, the bracket that holds the fuel filter is actually broken at the mounting point from the accident.

Fromage said:
Remove the steel valve cover cover. There is a nice aluminum underneath. You will need the clearance.
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I was wondering why your engine was topped with a nice silver cover.

Fromage said:
I think the tranny vent will hit the floor. You may want to extend it with some hose.
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I actually still need to install all the vent lines from the A442F as well as the trans cooler lines from the A442F

Fromage said:
Did you figure out the coolant elbow?

Looking really good!
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Not yet, I plan on checking that out this coming weekend. I really don't get to do anything on my projects during the week since I have our little bundle of joy at nights.

Thanks!
 
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