My 3 linked daily driver build thread

[LandCruisinMy93]

Status report: have flywheel, sent flywheel and clutch pressure plate to get balanced. Got flywheel back, removed oil pan to fit the windage tray (required some modifications) that I originally wasn't going or worry about, replaced gasket and bolted up pan. Bolted up intake manifold, still waiting on getting the intake adapter welded up. I need to also figure out how to get the engine and transmission to my brothers house where I will utilize his garage to do the swap. Apparently the flatbed trailer is still full of my last project he said he'd take to the scrap yard and my powerJoke f350 is currently sitting at his place uninsured since it too is a project I never drive. So, figuring out logistics and the one part and it's a go. Hopefully start it this week.

 

[LandCruisinMy93]

well, here's the good and the bad. The good: everything fits together well and the engine and trans/x-fed case are all one unit awaiting transport and install. The Bad: due to the bellhousing size, the starter mounting bolts are located inside the bell housing. So, should the starter need replaced either I will need to drill some holes and sleeve them at a later date, or I will need to remove the transmission. Or I suppose you might be able to disassemble the starter in place leaving only the front housing and install the new starter guts etc.. either way, there was no good way around it. And the final pictures before I get to swapping it all. I will of course test start it again outside the vehicle once I fill the trans and transfer case with fluid. I would like to rig up a clutch pedal and test that too before beginning the tear down. We will see.

 

[LandCruisinMy93]

And it begins! This morning I pressure washed the engine bay as best as I could, picked up 5 gallons of diesel, Checked the new drivetrain and test fired. Test fire went well, runs nice and smooth. Drained the radiator, power steering, and trans cooler, disassembled the front end. Got the engine disconnected with the exception of the fuel filter, motor mounts and trans mount. The old drivetrain is ready to come out. Didn't have a chance to Taken many pics so here is what I have.

 

[LandCruisinMy93]

Got the engine and transmission out, managed to somehow break a brake line on the driver side. Not sure yet, what I'm going to do to repair it. It is the hardline that runs down the frame to the rear and connects to a 90* fitting on a bracket just below the master. I cut the old motor mounts off the frame and messed around trying to get the new engine and transmission situated. It seems that the engine hoist just doesn't have enough reach. I will remove the rest of the core support today to try and gain the last few inches. Also, the compound turbo setup makes it a bit cumbersome and difficult to fit. It all measured out close to the old drivetrain, there are just some differences here and there that are preventing it from fitting easily. I have to run the remains of an old project to the recyclers today, but hopefully all have the new drivetrain situated and hard mounted by day's end.

 

[LandCruisinMy93]

Update August 1,2017 yesterday was a waisted day. I took the old project to the recyclers because my brother told me a month and a half ago that he would, then decided it needed to be gone yesterday. Recyclers wouldn't take it without more paperwork than I had; so I spent a few hours at the DMV getting that and made a return trip. By the time I got back to the project my brothers friend showed up to borrow the trailer. The trailer lights weren't working so I got to mess arround and figure that out for him at my brothers request. Seems I'm doing more crap for him than I am on my project. Such is the price paid for living in an apartment. Anyway, took the engine and trans back out, removed the rest of the core support which surprisingly changed nothing because somehow the cruiser with set parking brake and dual wheel chocks had rolled back 5 or so inches lol, can catch a break. Anyway, a friend of mine decided he's coming down today to help, so maybe we will get it hard mounted today, maybe I will waste another day trying to explain everything to him...he's a middle school teacher and intermediate mechanic who likes to know how everything works. Enough rambling, time to get to work.

 

[LandCruisinMy93]

Thursday August 3rd update. Well, the last 2 days have been 108* so work goes a little slower than I'd like because I'm roasting. However, I managed to get some traction Tuesday when my buddy came down. Between the two of us we got the engine and transmission situated and got the trans crossmember mocked up. That one step facilitated a lot of progress. Wednesday I disassembled the crossmember and made some changes and modified it to work with those changes. Got the motor mounts measured and the transmission tunnel massaged slightly for the part time case. Today I laid out the mounts and cut and drilled them and made plates to weld to the frame that the mounts would be welded to. Tac welded the mounts in and reinstalled the drivetrain....I've got some oil leaks and I'm not sure how and from where since it's all new gaskets and seals. I will check those out before the final installation. Tomorrow the drivetrain comes out again, motor mounts are moving 1/2 - 3/4" backwards. I dropped my rear driveline off at the driveline shop with new u-joints and the new length and picked up a double flare union to repair the brake line. I will pick up some undercoating spray and chassis paint if I can find some. Tomorrow the engine and transmission mounts will be done for sure. I will hopefully be able to move on to bolting on the accessories and reconfiguring the turbos. I also need to find a new Double Cardan for the front driveline since the one I had on there doesn't match up to the fj62 front transfer case output. Lastly, the shifter on the transmission pokes right through the original hole in the floor and doesn't interfere with the dash or anything! Like it was meant to be! The transfer case lever is yet to be determined lol. The AC hose routing is the one thing that I'm still working on, not sure how I should route the hoses since the compressor is on the opposite side from stock. Also need to figure out the throttle and cruise situation. I will get the power steering hose made soon. We will see how everything goes. Sorry for the long lost and shortage of pictures.

 

[LandCruisinMy93]

August 3rd pictures continued

 

[LandCruisinMy93]

August 5th, got the engine and transmission hard mounted. Replaced the rear heater lines with some from the wrecking yard, they look way better than mine did even before being smashed. Got the upper link mount cut off and the frame plates and the mount re-welded. Got the trans mount revamped and it will get finished tomorrow. The transfer case shifted bracket still needs clearanced some at the top. Got the broke brake line mended also. Otherwise plumbing begins as soon as the trans mount is done. Not sure how I'm getting both turbos under the hood in the space I have, but I'm sure it will come to me. I have to figure out which switches are which on the original transfer case and come up with a new hollow bolt one size larger to remedy the oversized hole that was drilled tapped for the manual shift conversion. It's coming together finally.

 

[LandCruisinMy93]

August 6th update, well it was a late start to the day (3:30) had a guy interested in my T100 project come look at it, he was suppose to be here in the early AM and didn't get here until 11:30, then he hem hawed and told me his and everyone he knew life stories. Anyway, got some work done to the transmission crossmember, gusseting and plating it for a more rugged design and better appearance, I will finish the rest tomorrow and grind, sand and paint it. Got the wiring harness labeled and removed from the 1FZ-FE and will begin gutting that tomorrow also. Got the alternator re-mounted and the oil pressure gauge installed. Hooked up the fuel return from the diesel to the hardline on the cruiser... direct fit. Unscrewed the fuel filter line at the fender well and cut the crimp off the line and I us d the left over thread on nipple to connect the fuel supply line, need to pick up appropriate sized supply line tomorrow along with some more plumbing fixens. It's coming together, going to finish the above, gut the wiring and plumb what I can tomorrow. Maybe even get some wiring done. Still have to figure out the turbos and intercooler, hopefully soon. Physical therapy on the 8th and have to take the mother to shoulder surgery the 10th so I'm losing days all over the place. Would t have been an issue if I had got my flywheel in June like I was supposed to. On to some pictures.

 

[LandCruisinMy93]

Well, my machinist said Friday before last (July 7th) that they had just completed the turn work on my flywheel and where preparing to put it in the end mill for bolt pattern and locating pin work and that I should have it sometime next week (last week) so
Maybe this week... we will see. If everything fits correctly and that's a big if. Then I will have it neutral balanced at a local automotive machine shop and get on with this way overdue swap.

 

[LandCruisinMy93]

Post #159,160 show the current progress. Got my flywheel yesterday and had to drive out to my brothers and reclaim the cherry picker to get the engine off the stand for rear main seal replacement and to fit the adapter plate, flywheel, clutch, throwout bearing and arm and bellhousing with the faux transmission. Everything seems to be aligned and the flywheel is a TIGHT fit to the Crank. The machining is excellent and the flywheel is a slight press fit onto the crank and the locating dowel and bolt holes line up perfectly. The counter bored holes are perfect size for the cap head bolts I'm using for flywheel bolts...don't worry, they're the same grade as the stock bolts. I will call around tomorrow and get the flywheel in for balancing. Time to move forward with this project.

 

[White Stripe]

Heat wrapping the exhaust manifold seems like asking for trouble. How will the heat be dissipated?

 

[LandCruisinMy93]

Heat wrapping the exhaust manifold seems like asking for trouble. How will the heat be dissipated?

The idea is the same as wrapping most any turbo exhaust manifold, the idea is the insulate the manifold because exhaust gases drive the turbine, the hotter the gas the better the efficiency to a certain extent. The main reason I wrapped it was to insulate the external wastegate from the manifold and rest of the hot parts. Wrapping and turbo blankets are also used to keep under hood temps down, should the exhaust manifold become an issue I can unwrap it. The plan is to build a custom tubular manifold and custom intake in the future after the thing is running and tested. So, the wrap is an interem solution.

 

[LandCruisinMy93]

Got the engine loaded and transported lastnight, had a heck of a time loading it and damaged some stuff due to a lack of care on my helps part. I have to replace the rear wheel bearing on a 2001 Audi A4 to make room in my brothers garage before I can start the swap, so that's today's task and hopefully tomorrow I can get the engine offloaded and begin the swap.

 

[LandCruisinMy93]

August 6th continued...Sorry for the broken thread, apparently I didn't save enough spots for pics and updates, this thing is all out of order. Can anyone tell me what the 3 switches circled on the transfer case are? I can't find the FSM at the moment and not having a lot of luck googlin or searching the answer. May be due to being burnt out, dehydrated and starving also. And lastly, anyone have any idea how to wire an internally regulated B+ D+ style 2 wire alternator to the factory wiring? Perhaps @pinhead the oracle of all things 80 series may know? I'm sure I can figure it out, but would like to save some time if I can and if someone has firsthand knowledge here.

 

[nukegoat]

Lovin it. I have that same jack from harbor freight. Its a heavy piece but works well

 

[ppc]

Top circle switch is the CDL Indicator
Bottom circle on the left is the transfer case neutral and right is the 4 Low

 

[LandCruisinMy93]

@nukegoat, the jack is my brothers but I have a similar higher rated one at home. It worked great to get the transmission up high enough, only needed one 4x4 block to get it there. @ppc thank you for the switch ID's I can gut the transfer case harness now.

August 7-8 update. Got the rear heater lines replaced and plumber. Got the heater core mostly plumbed. I gutted most of the wiring harness out and also finished the fuel lines. Mounted the stock turbo and the air cleaner to see what kind of room I have to work with for the second turbo and there isn't really much to work with if any. I guess I will figure it out eventually or end up figuring something else out.

 

[Tapage]

I'm dying to see / ear this engine boosting !

 

[LandCruisinMy93]

I'm dying to see / ear this engine boosting !

Me too buddy @Tapage, me too. Hopefully can get both turbos under the hood.

August 9th update, another late start today, had to go pick up some more 1/2 heater line and drop off both my power steering hoses to have 1 made. Also had to drive around to find somewhere that carried the proper gauge of wire for the alternator extension. Also had to got to the hardware store for some fasteners and wiring terminals. I was supposed to have the hose in and hour or two so I did a parts run then sat around waiting for the call so I didn't have to run back into town. They never called and I left to work on the truck around 2:30. Got the plumbing for the heater cores finished, got the alternator wiring ran through the headlight/core support loom to the fuse box and fusible link. De-pinned the AC trigger wire and brought it back to the driver side at near the fuse box and soldered the Mercedes terminal onto it and assembled it to the AC plug. Re-loomed the core support harness and de-pinned the rest of the wiring harnesses. Loomed the transmission/transfer case harness and starter circuit separately and ran the harness into the cab. Also, I extended the wiring for the oil pressure sensor and loomed that and attached it. A ring terminal for the starter signal wire, adding the backup lamp switch socket, figuring out if I can use the Mercedes coolant sensor, wiring the glow plug relay, wiring the Dakota digital tach converter, Coming up with and wiring a vacuum solenoid for shutoff, and deciding if I'm going to attempt a clutch switch of some sort are all that's left of the wiring. Radiator hoses are all that's left to figure out for the cooling system. I ordered new motor mounts so I will swap those in before buttoning up the front. All that will be left is clutch pedal installation, master cylinder installation, clutch line installation, clutch bleeding, front end assembly and figuring out the turbo situation.