Do you know what this part is for? I thought maybe it was something for the steering support drop down, but I have idea why it would have holes in it.
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Builds My Cummins 6bt / '92 fj80 build
- Thread starter Jvoight
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Dirty Koala
SILVER Star
I would love to see a detailed write up on how you put this together as my 6BT is about to get transplanted.1992 gmc safari and ended up using matching master cylinder as well... I have learned a ton about hydro swapping. Several guess and checks, multiple oversights, but finally after a ridiculous amount of research with no definitive answers I really have a grip on how they work and y mine seemed to be problematic. Push rods on both sides of the booster was the snag, they really have to be the correct length. I focused on the booster to MC rod and assumed the pedal to booster rod length was good... Reality is that pedal arm rod was 1" too long. Throwing all of it off. All is better nowlots of safari and astro vans in the 90's came with hydro boost for some reason plus another thread here on mud used that model so I did same... I'll try to document the hydro boost conversion and details soon.
- Did the 92 safari booster mate the the 4 firewall holes, or did you have to fabricate/drill new holes.
- Were the line fittings on the safari master the same as the toyota brake lines, or did you need to put new fitting on the brake lines.
- what did you do for hydrualic hoses from PS pump to booster and steering box?
- How did you handle the push rod lengths
- lastly, where did you find all your parts?
- Thread starter
- #83
I would love to see a detailed write up on how you put this together as my 6BT is about to get transplanted.
I WILL BE DOING A WRITE UP ON THE WHOLE SWAP SOON AS I CAN. I'LL NEED TO GET SOME GOOD PICS TO GO WITH IT. IF YOU NEED HELP OR INFO SOONER SEND ME A MESSAGE
- Did the 92 safari booster mate the the 4 firewall holes, or did you have to fabricate/drill new holes? A: I MADE A NEW PLATE AND WELDED BOLTS TO THE PLATE TO REACH THROUGH THE FIREWALL. THE PLATE HAS A LARGE HOLE THAT THE BOOSTER GOES THRU AND IS HELD ON BY A LARGE NUT.
- Were the line fittings on the safari master the same as the toyota brake lines, or did you need to put new fitting on the brake lines. A: INSTALLED NEW FITTINGS ON THE OE LINES THAT MATCHED THE SAFARI MC.
- what did you do for hydrualic hoses from PS pump to booster and steering box? A: MADE UP 2 HYDRAULIC HOSES. PUMP TO BOOSTER, BOOSTER TO POWER STEERING BOX... RETURN LINE FROM BOTH THE BOOSTER AND P.S.BOX.... MY P.S.PUMP RESERVOIR ALREADY HAD THE SECOND RETURN LINE PROVISION.
- How did you handle the push rod lengths. A: SEVERAL FAILED ATTEMPTS AND TONS OF FRUSTRATING RESEARCH ON THE WEB. THERE IS NOT A REAL" THIS IS HOW LONG THEY SHOULD BE" THERE IS HOWEVER A PROPER PROCESS TO GO THROUGH.
- lastly, where did you find all your parts? A: LOCAL AUTO PARTS STORE, BOUGHT NEW. THE EXCEPTION TO THIS IS THE MC PUSH ROD, RETURN SPRING, PLASTIC WASHER AND SPRING RETAINING WASHER. IT'S NEARLY IMPOSSIBLE TO JUST BUY THESE ITEMS. I DON'T KNOW Y BUT IT IS.
Dirty Koala
SILVER Star
Thank you. I look forward to seeing those pics
- Thread starter
- #85
2 weeks and 800 miles review...
This has been good couple weeks. First off it drives awesome. I've had some minor issues to deal with... That initially seemed to create an overreaction to just how big the issues were. Let me get started on the bugs that got worked out. I was a lil delusional in thinking pfffft... I won't have any bugs...
1) coolant leak #1 thermostat housing!
Freaked out a tiny bit then discovered it was just a bad thermostat seal. Fixed.
2) coolant leak #2 90% sure it's very small crack in OE radiator near cap that seems to only leak when cold. Open to suggestions on replacements...
3) valve cover gasket leak ON the very back cover next to fire wall. This was another oh sh#t moment because I was mostly convinced my new rear main seal didn't seal. THE oil runs down and collects at the bell housing like a rear main leak. That would've sucked! Got set of new gaskets will install today.
4) bad fuel lift pump and slow starting... Needed a new lift pump for sure, installed a new one from local Cummins dealer. Runs better now but still doesn't start as quick as I feel it should... especially when warm. Ideas?
It is really going well, and pulls 4th gear really well. 2nd and 3rd gear I wish performed a Lil better... From an acceleration standpoint. It is bone stock at this point. Anyone change fuel plate?
THE switch to the 343 trans is a really nice change and upgrade from the 440... I do miss the 3rd gear option tho. The viscous couple is way smoother.
Fuel mileage is really good. Best being 19.8 mpg then a 16.8 mpg (towing boat and getting on it a fair amount
) and then back to a 19.1mpg
Going on a 300 mile road trip tomorrow. UP over the Santiam pass to Bend OR. Looking forward to it.
This has been good couple weeks.
First off it drives awesome. I've had some minor issues to deal with... That initially seemed to create an overreaction to just how big the issues were. Let me get started on the bugs that got worked out. I was a lil delusional in thinking pfffft... I won't have any bugs...1) coolant leak #1 thermostat housing!
Freaked out a tiny bit then discovered it was just a bad thermostat seal. Fixed.
2) coolant leak #2 90% sure it's very small crack in OE radiator near cap that seems to only leak when cold. Open to suggestions on replacements...
3) valve cover gasket leak ON the very back cover next to fire wall. This was another oh sh#t moment because I was mostly convinced my new rear main seal didn't seal. THE oil runs down and collects at the bell housing like a rear main leak. That would've sucked! Got set of new gaskets will install today.
4) bad fuel lift pump and slow starting... Needed a new lift pump for sure, installed a new one from local Cummins dealer. Runs better now but still doesn't start as quick as I feel it should... especially when warm. Ideas?
It is really going well, and pulls 4th gear really well. 2nd and 3rd gear I wish performed a Lil better... From an acceleration standpoint. It is bone stock at this point. Anyone change fuel plate?
THE switch to the 343 trans is a really nice change and upgrade from the 440... I do miss the 3rd gear option tho. The viscous couple is way smoother.
Fuel mileage is really good. Best being 19.8 mpg then a 16.8 mpg (towing boat and getting on it a fair amount
) and then back to a 19.1mpgGoing on a 300 mile road trip tomorrow. UP over the Santiam pass to Bend OR. Looking forward to it.
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- Thread starter
- #86
Oh... on another note I'd like to hear what rpm's you guys are running at freeway speeds along with what tire size your running... 60,70,75mph.
My tach isn't hooked up yet but should get the part from Dustin next week.
I feel like I'm glad I'm running 35" by the way it sounds doing 70... On the freeway. I'll find out where it's running at next week
My tach isn't hooked up yet but should get the part from Dustin next week.
I feel like I'm glad I'm running 35" by the way it sounds doing 70... On the freeway. I'll find out where it's running at next week
- Thread starter
- #87
I weighed it at the scales the other day and it is sitting at 5400 lbs.
I changed fuel plate, APC spring, and gov springs at the same time. Night and day difference afterwards.
When you start your up do you give it fuel or key only? Mine I have to tap the skinny pedal and it fires right up. Without it will crank over for a bit if cold.
When you start your up do you give it fuel or key only? Mine I have to tap the skinny pedal and it fires right up. Without it will crank over for a bit if cold.
- Thread starter
- #89
- Thread starter
- #90
Thanks for the info... The touching the skinny pedal totally fixes the slow start issue... I was doing key only starts. What # fuel plate did you do? Thanks.
I believe it's #10 but don't quote me on that. Can't access my notes at the moment.Thanks for the info... The touching the skinny pedal totally fixes the slow start issue... I was doing key only starts. What # fuel plate did you do? Thanks.
- Thread starter
- #92
So after driving from Brownsville (home) to Pacific City Oregon over to Bend Oregon (for my daughter soccer game) then back to the beach house in Pacific City we pulled off a Sunday afternoon lake run to Green Peter reservoir near Sweet Home Oregon. Feels really good to get some great use out of this transformed cruiser... Still has all the incredible fj80 feel we love just with excellent power and fuel mileage added to the equation hard to imagine a better 8 passenger rig. Was wild to pass with ease in short pass lanes going up and over the Santiam pass ... MY wife and I both just smiled. We were both thinking... Well that's new! I wouldn't say this swap is an easy undertaking... but it is so worth it when you get there. Just taking the time it requires to do it right, the best you can... goes a long way in the end.
hard to imagine a better 8 passenger rig. Was wild to pass with ease in short pass lanes going up and over the Santiam pass ... MY wife and I both just smiled. We were both thinking... Well that's new! I wouldn't say this swap is an easy undertaking... but it is so worth it when you get there. Just taking the time it requires to do it right, the best you can... goes a long way in the end.
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- Thread starter
- #93
Here is a good pic of my older brother's really clean fj62... up at the lake with us yesterday.
- Thread starter
- #94
Here another cool pic from Pacific City... It really is one of the Oregon coast's best stops. In-laws rented a house for the weekend... Was really nice especially being front row.
That's pretty sweet. Just got back from seaside yesterday. I wanted to find a place to drive on the beach but I guess I was too far north. Looks good man keep up the good work!
It's a great spot. Was just there in Aug. Friends rented one of the little cabins for the weekend.
- Thread starter
- #97
Would be way cool to meet up with any of you guys... Sand Lake sand dunes would've been a good stop its near Tillamook... Or farther south Florence sand dunes are really cool and a much bigger area... Pacific City is really just beach driving but still way neat.
You are not too far from us. We typically head over the North Bend dunes. Some are planning a trip pretty soon. Anyway always free to join or chime in here: OR/CA- Jefferson State Cruisers
- Thread starter
- #99
Happy birthday to my awesome and patient wife who tolerated quite a bit during the last 5 months... admitting she had thoughts only A few times that I might be in over my head on this swap! 
Thanks for your support and help babe!
Thanks for your support and help babe!
- Thread starter
- #100
Going up to see Dustin today to get my tachometer magic device...
