Any updates? I hope you are getting to enjoy it!!!
My 75 FJ40 build up thread
- Thread starter kcustom73
- Start date
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sweet truck ... congrats! ... that blue may be a Heep colour but its a dead ringer for FJ Cruiser Voodoo Blue ...
WOW what a build.
Est. 2007
GotRdone! Nice.
Est. 2007
GotRdone! Nice.
kcustom73
Stretched it...
- Thread starter
- #244
Well I've been driving the 40 for a few months now. It drives great both on city street and the highway. With summer camping trip with the family and the travel trailer, I haven't had a chance to take it off road yet.
I did run into a few problems with it on my last highway trip. Cruising at around 62mph, everything is good but any faster then that, the temperature start to climb. Need to look at the airflow and the electric fan (volvo/taurus).
Also when I got back from the trip I put the 40 in the garage and went in for supper. A buddy of mine show up later in the evening and we head out to the garage to find a puddle of gear oil under the transfercases. I checked the levels and the oil is coming from the 203 doubler. The leak is always there, so I've parked it for now and I've ordered gasket so I can rip this thing apart to see whats going on.
I did run into a few problems with it on my last highway trip. Cruising at around 62mph, everything is good but any faster then that, the temperature start to climb. Need to look at the airflow and the electric fan (volvo/taurus).
Also when I got back from the trip I put the 40 in the garage and went in for supper. A buddy of mine show up later in the evening and we head out to the garage to find a puddle of gear oil under the transfercases. I checked the levels and the oil is coming from the 203 doubler. The leak is always there, so I've parked it for now and I've ordered gasket so I can rip this thing apart to see whats going on.
kcustom73
Stretched it...
- Thread starter
- #245
I've had a lot more time to drive the 40 lately.
Finally figured out where the leak from my transfer cases came from. Here's a separate post on the whole ordeal of fixing it: 203 doubler - 88 splicase leak
Now the transfer case situation is fixed, the 40 drives better then ever. after driving it a bit, there's a few things I want to do to the 40 over the winter:
1-modified the transmission hump. Because of how it's designed, there's a lot of heat building up at the back end of it. Want to rework to get some more air flow going through and also maybe give myself a little more room to route the heater lines to the back heater
2-front bumper and Warn 8274
3-little more acoustical insulation... I know it a 40... but going to try and cut down on some of the engine noise.
4- change trans temp gauge... the one I've got now is useless. The from 150 to 200 is so narrow, I have no clue what temp the 4L80e is at
5-After my last off-road trip... I really need a skid plate for the tcases
Speaking of off-roading here are some pics and video's of my first real off-road trip with fellow members of the True North Toyota Land Cruiser club.
And here's a quick video of my 40 in action.
http://vid181.photobucket.com/albums/x177/kcustom73/thanksgiving 2015-1_zpsptu21anh.mp4
Finally figured out where the leak from my transfer cases came from. Here's a separate post on the whole ordeal of fixing it: 203 doubler - 88 splicase leak
Now the transfer case situation is fixed, the 40 drives better then ever. after driving it a bit, there's a few things I want to do to the 40 over the winter:
1-modified the transmission hump. Because of how it's designed, there's a lot of heat building up at the back end of it. Want to rework to get some more air flow going through and also maybe give myself a little more room to route the heater lines to the back heater
2-front bumper and Warn 8274
3-little more acoustical insulation... I know it a 40... but going to try and cut down on some of the engine noise.
4- change trans temp gauge... the one I've got now is useless. The from 150 to 200 is so narrow, I have no clue what temp the 4L80e is at
5-After my last off-road trip... I really need a skid plate for the tcases
Speaking of off-roading here are some pics and video's of my first real off-road trip with fellow members of the True North Toyota Land Cruiser club.
And here's a quick video of my 40 in action.
http://vid181.photobucket.com/albums/x177/kcustom73/thanksgiving 2015-1_zpsptu21anh.mp4
boozewz
SILVER Star
Great stuff….finally getting to enjoy what you built it for! Please do share more pics of the truck in her element!
It was monumental day indeed after all those years. Thanks for having the guts to take it out on the trail. Hope there are many more to come.
hecrod
40 & 930 Fanatic...
- Joined
- Jun 25, 2012
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Highlighting your build on this thread as follows (Excellent Work!!!):
My 75 FJ40 build up thread... this build took almost 8 years! From a truly rusted out 75 to a stretch out beauty! Can you say 6.5L turbo diesel??? Amazing skills... and persistence! Kudos to you Kevin... @kcustom73
From:
To:
My 75 FJ40 build up thread... this build took almost 8 years! From a truly rusted out 75 to a stretch out beauty! Can you say 6.5L turbo diesel??? Amazing skills... and persistence! Kudos to you Kevin... @kcustom73
From:
To:
kcustom73
Stretched it...
- Thread starter
- #249
Thank you hecrod. Bob (my daughter named the 40) is now parked for the winter. The amount of salt they put on the roads in our area is insane. I don't mind putting a few dings it from me driving it but have it rot away again after the time I've put into it... Now I'm going the winter tinkering on the 40 and helping a friend getting his 66 IH Scout on the road. Should be a good winter.
kcustom73
Stretched it...
- Thread starter
- #250
The story continues....
Almost a year since I've update this thread. So last winter I spent some time fabbing up a new cross-member to raise the transfer case a little for trail clearance and also fab up some skid plates. Also added some sound deadening to make a bit quieter.
From day one I always found my 40 to be noisy (mostly caused by vibration). After being at stop light in my Canyon (super quiet) beside a pickup with 6.5 diesel turbo in it that had was way quieter then my 40, I realized that something was wrong with mine. So this spring I started trying to figure out what was wrong. After tons of research and trying things, I figured out it was the flexplate that was warped. So mid summer I'm under the 40 pulling everything out to get the flexplate changed. While doing this I also figured out that I haven't fixed the oil leak in my t-case setup. So after the flexplate is changed, drive the 40 a bit and figure that the torque might be on its way out (still have to do some investigating) and that the 203 still leaks (splitcase isn't loosing any oil). So now the 40 is parked early for the season with only about 1500km driven this season...
Getting tired of trying to fix the 40 but pig headed to let it go. So I'm thinking of pulling the 203 doubler out of the system and just mating the splitcase to the 4l80e. From the off roading I have done with the 40, I don't think I need the extra gearing (the auto trans torque converter and the low end oomphs of the diesel make off roading with less gearing easier and the trails I did last summer was at the limit of my comfort zone).
So the plan for this fall:
Get an AA adapter to mate the 4l80e to the splitcase
shorthen/lengthen driveshafts
new crossmember?
adjust skid plate
Flex joint for the exhaust
winch and bumper
few other minor items
So all this while helping my buddy get his IH Scout on the road. Hopefully I get this thing reliable so I can put some mileage on it.
Stay tune for some pics.
Almost a year since I've update this thread. So last winter I spent some time fabbing up a new cross-member to raise the transfer case a little for trail clearance and also fab up some skid plates. Also added some sound deadening to make a bit quieter.
From day one I always found my 40 to be noisy (mostly caused by vibration). After being at stop light in my Canyon (super quiet) beside a pickup with 6.5 diesel turbo in it that had was way quieter then my 40, I realized that something was wrong with mine. So this spring I started trying to figure out what was wrong. After tons of research and trying things, I figured out it was the flexplate that was warped. So mid summer I'm under the 40 pulling everything out to get the flexplate changed. While doing this I also figured out that I haven't fixed the oil leak in my t-case setup. So after the flexplate is changed, drive the 40 a bit and figure that the torque might be on its way out (still have to do some investigating) and that the 203 still leaks (splitcase isn't loosing any oil). So now the 40 is parked early for the season with only about 1500km driven this season...
Getting tired of trying to fix the 40 but pig headed to let it go. So I'm thinking of pulling the 203 doubler out of the system and just mating the splitcase to the 4l80e. From the off roading I have done with the 40, I don't think I need the extra gearing (the auto trans torque converter and the low end oomphs of the diesel make off roading with less gearing easier and the trails I did last summer was at the limit of my comfort zone).
So the plan for this fall:
Get an AA adapter to mate the 4l80e to the splitcase
shorthen/lengthen driveshafts
new crossmember?
adjust skid plate
Flex joint for the exhaust
winch and bumper
few other minor items
So all this while helping my buddy get his IH Scout on the road. Hopefully I get this thing reliable so I can put some mileage on it.
Stay tune for some pics.
Hi Kevin - I plan to stretch my FJ40 chassis too. Where did you got/buy that extension piece? It's nicely flash with the original frame. Thanks.
I did manage to get the frame to the fabricator this summer and have him add 27" to the frame. Also had him repair the back part of the frame and box everything in.
I also managed to finish most of the repair work to the from cowl. This link is what I started with: cowl before repairs, and the picks below is what I finished with. There is still a little welding to do but it can wait for a bit.
passenger side
driver side
Now its time to drop the cowl back onto the frame and start making some new body mounts for the tub, then motor mounts, tranny mounts, stretch the sides, stretch the roof.... Going to be a busy winter
[/QUOTE]
I did manage to get the frame to the fabricator this summer and have him add 27" to the frame. Also had him repair the back part of the frame and box everything in.
I also managed to finish most of the repair work to the from cowl. This link is what I started with: cowl before repairs, and the picks below is what I finished with. There is still a little welding to do but it can wait for a bit.
passenger side
driver side
Now its time to drop the cowl back onto the frame and start making some new body mounts for the tub, then motor mounts, tranny mounts, stretch the sides, stretch the roof.... Going to be a busy winter
[/QUOTE]
Kevin, I just read through your build and I thoroughly enjoyed it! Great work and congrats on sticking with the project and coming out with a finished product. I am thinking about having the same drivetrain setup in my FJ62. Would you do it all over again, the same setup or what would you change?
I already have a mechanical 6.5 from a 1993 Chevy truck with a 4l80e and the stand alone trans controller. Then I would just need to pick up a 203 and adapter from advanced.
I plan on running stock 62 axles until I could possibly find some 80's axles with factory lockers while running 33's or 35's.
What are your thoughts?
I already have a mechanical 6.5 from a 1993 Chevy truck with a 4l80e and the stand alone trans controller. Then I would just need to pick up a 203 and adapter from advanced.
I plan on running stock 62 axles until I could possibly find some 80's axles with factory lockers while running 33's or 35's.
What are your thoughts?
kcustom73
Stretched it...
- Thread starter
- #254
Bronxxx, interesting project of putting that drivetrain combo into a FJ62.
The 6.5 turbo I've got is a built engine and really moves my 5500lbs Fj40 (this is with 3.7 gears)
If you can, get the Transgo HD2 shift kit for the 4L80e. Makes a huge difference on how the transmission works.
As for the 203, I'm taking it out of the truck this winter. I've personally had all sort of leaking problems with it. Also, because of the space constraint of the 40, I had to go to a 2 piece front driveshaft that I've never been able to get it to balance properly. So with no 203, the leak will be gone and I should be able to go back to a one piece driveshaft on the front. I know that Boots and Chicago here on IH8MUD have a similar drivetrains and have not had issues that I know of. For the off-roading I do, I've never needed the extra gearing. The low end of the 6.5 combined with the slippage of the torque converter of the 4l80e has gotten me as far as my nerves will take me and then some. I am planning on going back to 4.1 gears this winter as I feel that the engine is lugging around to much. Going back to 4.10 will bring my rpm's back up and I hope it will give the 40 a little more pep. The 4.10 will also help out in the off-road department.
For the 203, it all depends on what kind of driving you. I know the adapter for the 203 to splitcase is made by Advance Adapters but isn't sold by them. I got mine from Mudrack here on MUD. However, if you still plan on going with the 203 and are not it a hurry, my adapter will be for sale sometime early next year (probably February).
The 6.5 turbo I've got is a built engine and really moves my 5500lbs Fj40 (this is with 3.7 gears)
If you can, get the Transgo HD2 shift kit for the 4L80e. Makes a huge difference on how the transmission works.
As for the 203, I'm taking it out of the truck this winter. I've personally had all sort of leaking problems with it. Also, because of the space constraint of the 40, I had to go to a 2 piece front driveshaft that I've never been able to get it to balance properly. So with no 203, the leak will be gone and I should be able to go back to a one piece driveshaft on the front. I know that Boots and Chicago here on IH8MUD have a similar drivetrains and have not had issues that I know of. For the off-roading I do, I've never needed the extra gearing. The low end of the 6.5 combined with the slippage of the torque converter of the 4l80e has gotten me as far as my nerves will take me and then some. I am planning on going back to 4.1 gears this winter as I feel that the engine is lugging around to much. Going back to 4.10 will bring my rpm's back up and I hope it will give the 40 a little more pep. The 4.10 will also help out in the off-road department.
For the 203, it all depends on what kind of driving you. I know the adapter for the 203 to splitcase is made by Advance Adapters but isn't sold by them. I got mine from Mudrack here on MUD. However, if you still plan on going with the 203 and are not it a hurry, my adapter will be for sale sometime early next year (probably February).
kcustom73
Stretched it...
- Thread starter
- #255
So my 40 is going under the knife this winter. After driving it for a few early spring to late fall seasons there's a few things I've decided to change.
1- with my 40 weighing in at 5500lbs (no people or gear) I was always worried about the strength of the rear semi float axle (GVWR for my 40 is 4860lbs, truck, people & gear total). So after chatting with some other local Cruiser folks, I was able to source a full float 78 FJ45 rear axle. With the 45 rated at 6700lbs GVWR, I will feel comfortable putting people and gear into my 40. A call to Cruiser Outfitters and all the parts to rebuild the axle are on their way.
2- I've decided to get rid of the 203 doubler. I've spent a lot time and effort trying to get this setup not to leak and I'm tired of fitting with it. So I will remove it and just go to the AA adapter to mate the 4L80e to the splitcase.
3- Going back to 4.1 gear in the diffs. When I built the 40 I put in 3.7 in the diffs with the hope of better road manners, but with the 203 gone, I wanted a little more low gearing. The rear is easy because of the full float swap already has 4.1. I also have a complete 3rd member from FJ62 sitting under the work bench that I will clean up and pop in. This will help on the low side, but will bring my RPMS up a bit which I feel my engine needs as I think I'm lugging the thing around at too low and RPM.
Some other minor projects will go with the major ones but I'm hoping that this version of my 40 will be its last for a while... Stay tuned for some pictures.
1- with my 40 weighing in at 5500lbs (no people or gear) I was always worried about the strength of the rear semi float axle (GVWR for my 40 is 4860lbs, truck, people & gear total). So after chatting with some other local Cruiser folks, I was able to source a full float 78 FJ45 rear axle. With the 45 rated at 6700lbs GVWR, I will feel comfortable putting people and gear into my 40. A call to Cruiser Outfitters and all the parts to rebuild the axle are on their way.
2- I've decided to get rid of the 203 doubler. I've spent a lot time and effort trying to get this setup not to leak and I'm tired of fitting with it. So I will remove it and just go to the AA adapter to mate the 4L80e to the splitcase.
3- Going back to 4.1 gear in the diffs. When I built the 40 I put in 3.7 in the diffs with the hope of better road manners, but with the 203 gone, I wanted a little more low gearing. The rear is easy because of the full float swap already has 4.1. I also have a complete 3rd member from FJ62 sitting under the work bench that I will clean up and pop in. This will help on the low side, but will bring my RPMS up a bit which I feel my engine needs as I think I'm lugging the thing around at too low and RPM.
Some other minor projects will go with the major ones but I'm hoping that this version of my 40 will be its last for a while... Stay tuned for some pictures.
kcustom73
Stretched it...
- Thread starter
- #256
So the 2017/2018 upgrades are well under way.
The front diff has been swapped from 3.73 to 4.11.
The semi-float axle is out and the full float is in the mock up process. Installing new spring perches as the old ones where beat up. Also gives me a chance to get the pinion angles right without shims
View media item 67260
Also figured out that you can use FJ60 semi float axle disk brake conversion brackets on a FJ45 full float axle with spacer (all the holes all match). More pics to come once installed.
View media item 67264
Got rid of the A/C compressor (had gotten rid of everything else).
View media item 67262
New trans cross member is done and also had to shave 2wd/4wd sensor (wasn't being used any way)
View media item 67261
View media item 67259
Tons left to do to get it on the road for the spring but things are going well.
The front diff has been swapped from 3.73 to 4.11.
The semi-float axle is out and the full float is in the mock up process. Installing new spring perches as the old ones where beat up. Also gives me a chance to get the pinion angles right without shims
View media item 67260
Also figured out that you can use FJ60 semi float axle disk brake conversion brackets on a FJ45 full float axle with spacer (all the holes all match). More pics to come once installed.
View media item 67264
Got rid of the A/C compressor (had gotten rid of everything else).
View media item 67262
New trans cross member is done and also had to shave 2wd/4wd sensor (wasn't being used any way)
View media item 67261
View media item 67259
Tons left to do to get it on the road for the spring but things are going well.
Looking good Kevin!
Don't forget to mock-up with weight on the springs for setting the pinion angle or you'll end up with shims anyway!
Don't forget to mock-up with weight on the springs for setting the pinion angle or you'll end up with shims anyway!
a 40 is never done..... Do you set up your own diff's? Never done it and I may have to. Keep it up!
kcustom73
Stretched it...
- Thread starter
- #259
Andy, I got B&N to rebuild my diff for the full float but they messed up the preload on the pinion so I've decided to do it myself. I've got all the tools to do it now, just have to find the time to do it. Once I figure mine out, I can give you a hand with yours.
I spent the week putting the transfer case back in and rebuilding the shift linkages. Actually did a better job this time around on the linkages.
I spent the week putting the transfer case back in and rebuilding the shift linkages. Actually did a better job this time around on the linkages.
I think I would try and find another frame. Sounds like an awful lot of work and time in this one.
