Builds My R2.8 Cummins FJ40 (RJ40) daily driver build

[ArthurFJ]

I had a Split Case out of a 1986 FJ60 that I sent it out to Georg Esterer (Cruiser Brothers) in California had him completely rebuild my split case and attach it to a new H55 that he sold me. The H55 was a little less than $2,600. I thought about the NV4500 but the H55 setup is 4 to 5 inches shorter than the NV4500. I wanted to keep my rear drive shaft as long as possible and wanted to minimize tranny hump modifications. I am hoping to use my existing 4 speed tranny mounts which looks like same bolt locations for the H55.

That's all starting to sound pretty nice right now. I'm going through trying to see if I can get my rear diff centered so I can use an american transfer case instead of buying another adapter for my NV4500 to t-case and a toyota tcase which is a lot more than the american ones. Really I could have just lowered my highway RPMs by getting a smaller gear ratio set up in my diffs... might have been cheaper than my way of doing things.

 

[amico]

Wow that sounds like a real challenge. The H55 is really close to the NV4500 in overdrive .83 vs .75 ratio I believe. I guess another advantage for the H55 is the standard later FJ60 split case's will bolt up. I didn't even realize it would take another adapter or cause you to center your rear axle.

 

[ArthurFJ]

Wow that sounds like a real challenge. The H55 is really close to the NV4500 in overdrive .83 vs .75 ratio I believe. I guess another advantage for the H55 is the standard later FJ60 split case's will bolt up. I didn't even realize it would take another adapter or cause you to center your rear axle.

Yeah I think to get a Toyota Split case on an NV4500 you need an adapter. I just got off the phone with a guy that can center my rear diff.... $1500. Ugh

Sooooo maybe I'll just buy an Atlas Tcase. They're supposed to be pretty good and by the customization options it looks like you can have it built exactly to your specs

 

[amico]

if you move the rear differential do you have to move the front as well??? Both are passenger side.

 

[ArthurFJ]

No, the NP205 (and most tcases, from what I've seen) use a centered rear output and an offset front output to the passenger side. So I could leave the front end as it is.

 

[amico]

Yeah just saw a video. Good Luck.
And good luck on your color selection, already got mine picked.
Keep us posted I'll be watching your thread for updates.

 

[Salem747]

You are a few months ahead of me!

I am in Canada (BC, you mention you just left Calgary) so one of the (Exceedingly few for stuff like this) benefits of BC is that Cummins price includes shipping to my house!

I have 2 FJ40 (I think one is actually a BJ because it is diesel) cores that I am tearing into now.

I am thinking I will go aqualu on most of the body though (also one of those very few benefits is Aqualu is in Kelowna!).

I have been thinking NV4500 too, just for the strength and the potential for towing an overland trailer. Didn't consider the move of the diff input though. That is a PITA. Are you going quickdraw or advance adapters?

Have you seen Axis' stuff? pretty spendy but really nice.

Will be watching!

 

[ArthurFJ]

You are a few months ahead of me!

I am in Canada (BC, you mention you just left Calgary) so one of the (Exceedingly few for stuff like this) benefits of BC is that Cummins price includes shipping to my house!

I have 2 FJ40 (I think one is actually a BJ because it is diesel) cores that I am tearing into now.

I am thinking I will go aqualu on most of the body though (also one of those very few benefits is Aqualu is in Kelowna!).

I have been thinking NV4500 too, just for the strength and the potential for towing an overland trailer. Didn't consider the move of the diff input though. That is a PITA. Are you going quickdraw or advance adapters?

Have you seen Axis' stuff? pretty spendy but really nice.

Will be watching!

Nice! I'm going with quickdraw I think. Chad says he's also working on an adapter for a NV4500 to toyota 60 series split case, so that would solve the issue with the offset rear diff. Price would be around $500 he says.

Yeah I've seen some of it. It is super pricey. I'll probably be buying the engine mounts from them.

 

[Salem747]

I was thinking the same thing on Axis.

Although the $3000 cooling package does come with all the radiators, But a Mishimoto intercooler or rad of that size is only about $200-$300 each on Summit Racing, so not sure how they get to over $3000.

 

[ArthurFJ]

Over $3000?!?! what the hell? Try this: FlexALite 51160R - Radiator/Fan combo 17" core right inlet w/ #160 fan (Credit to AMICO!)

 

[amico]

Arthur, I am going with a different intercooler than the EMUSA (tube & fin) which I originally told you. I am going with a bar & plate type which I understand to be much more durable. The one I am using is:
Frostbite Universal Intercoolers FB602B which I hope doesn't block too much of the radiator.

 

[Salem747]

I agree it is expensive, but it does come with rad, intercooler, oil filter mount and I think the ac stuff. But yeah, you can get top end mishimoto stuff for way cheap. Just means you have to build your own mounts.

I am in the same thinking as you though, buy the motor mounts from someone like that, then you know it was done right. A wiggly rad I can fix, a wiggly frame gets tougher!

What state is your frame in? I am taking apart my first donor and it is rusty but doesn't look like it is perforated at all. Still need to decide on a stretch to the cab. I think I want to stretch but it means changes to the hardtop, frame, etc.

 

[Salem747]

So I am having a hard time figuring this transmission/tcase thing out. I can get an adapter from my R2.8 to most things that make sense. I was leaning NV4500 but then it sounded like a PITA so I started looking at the H55F but, if those used to be cheap, they aren't anymore!

 

[amico]

So I am having a hard time figuring this transmission/tcase thing out. I can get an adapter from my R2.8 to most things that make sense. I was leaning NV4500 but then it sounded like a PITA so I started looking at the H55F but, if those used to be cheap, they aren't anymore!

You can get a NEW H55 from Georg Esterer 1-209-475-8808 for around $2600 www.cruiserbrothers.com .Then you can install or have him install a later FJ60 split case then everything is closer to factory. Then you only need the adapter for the Cummins which Quick Draw sells as a direct bolt up.

 

[Will Van]

You can get a NEW H55 from Georg Esterer 1-209-475-8808 for around $2600 www.cruiserbrothers.com .Then you can install or have him install a later FJ60 split case then everything is closer to factory. Then you only need the adapter for the Cummins which Quick Draw sells as a direct bolt up.

View attachment 2014580

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R2.8 -> QuickDraw -> H55F -> Split Case = Awesome!

Edit: Just realized y’all were talking about the Axis cooling package earlier in the thread. Oops!

FWIW, Axis Industries is developing R2.8 kits for the FJ40. If you have seen any of their work in the Jeep world, it's very nice. Great attention to detail and elegant design.

The full Axis kit will ultimately include a cooling package (radiator, intercooler, A/C condenser), intercooler piping, oil cooler mount, engine mounts, bell housing adapter kit, and trans crossmember for the H55F.

Unfortunately due to "packaging constraints" the Axis bell housing adapter is a two-piece unit that goes from R2.8 to an LS adapter plate, then an actual bellhousing from LS adapter plate to H55F trans (I think the TorFab setup below is similar/identical). This adds the extra length between the back of the R2.8 and the front of the H55F transmsmission to place the 5-speed shifter in the stock location, but also move the R2.8 away from the firewall. Axis said the dimension needed to be about 8", and a direct-fit bell housing was only 6". Anybody know the dimensions on the QuickDraw?

The Axis setup also requires a ring gear for the starter, and a spacer for the flywheel. That's how they setup all of their Jeep conversions. The reasoning behind the two-piece bell housing is that they want the shifters to come up in the stock location, but the R2.8 is so short that it would place the motor really close to the firewall. So they extend the bell housing length with the multiple adapter plates.

I still think the cleanest setup is the R2.8, QuickDraw Bellhousing, H55F trans, and Toyota Split Case.

NV4500 would be really cool because of the gearing and strength, but it looks like it requires some fab work on the trans cover. And driveline length may be an issue. Advance Adapters makes a kit to run an NV4500 to Toyota split case. And people have been swapping NV4500s for decades with 350 SBC/GM/LSX conversions, so you would think a lot of this has already been worked out.


@amico - Do you have your QuickDraw bell housing yet? I'm just down the road from you in Austin.

 

[Will Van]

Nice! I'm going with quickdraw I think. Chad says he's also working on an adapter for a NV4500 to toyota 60 series split case, so that would solve the issue with the offset rear diff. Price would be around $500 he says.

FYI: Advance Adapters already offers an adapter for the NV4500 to Toyota 60 series split case. It replaces the NV4500 tail extension housing and utilizes a supplied spud shaft. You have to cut the NV4500 output shaft down for the spud shaft to fit.

Updated Advance Adapters NV4500 to 3 SPD Transfer Case Info

50-0214 : GM NV4500 4wd to Toyota Land Cruiser 19 Spline transfer case adapter. | Advance Adapters

 

[Salem747]

@Will Van Yeah, I also have the early pricing on the axis package, it's $3145 USD!!! Intercooler tubing is $533, AC add on is $486 and an AC compressor kit is $800. Like I said, it's nice stuff and all but wow, it's spendy.

I know I CAN do all this adapting but jeez, it's expensive and I am also a bit concerned with making this package really long. Quickdraw and FarmStrong have an NV4500 true bellhousing for the R2.8 (I think they shared the development). But, as you point out you need to fiddle with the tailhousing and get a tcase adapter.

I am still debating whether to do the 18" stretch or leave the length stock, obvs if I stretch the driveline angle won't be an issue AND I could probably easily find a rear mount fuel tank then. Waiting for my wife to come back from a trip so we can decide together.

I am wondering if I just get the Toyota to R2.8 Adapter, use one of the transmission/tcases I have (75 & 79) and keep my eyes peeled for a good deal on an H55F and a split case. The Quickdraw/Farmstrong adapt to both the H42 and the H55.

What are you thinking @ArthurFJ ?

 

[Salem747]

PS, ever thought of something cool to run off the PTO on the NV4500? Compressor, generator?

 

[Will Van]

@Will Van Yeah, I also have the early pricing on the axis package, it's $3145 USD!!! Intercooler tubing is $533, AC add on is $486 and an AC compressor kit is $800. Like I said, it's nice stuff and all but wow, it's spendy.

I know I CAN do all this adapting but jeez, it's expensive and I am also a bit concerned with making this package really long. Quickdraw and FarmStrong have an NV4500 true bellhousing for the R2.8 (I think they shared the development). But, as you point out you need to fiddle with the tailhousing and get a tcase adapter.

I am still debating whether to do the 18" stretch or leave the length stock, obvs if I stretch the driveline angle won't be an issue AND I could probably easily find a rear mount fuel tank then. Waiting for my wife to come back from a trip so we can decide together.

What does the $3145 price include? Just the cooling package (radiator, intercooler, and A/C condenser)? What is the “A/C add on”?

 

[Salem747]

Custom Part FJ40/45 Cooling Package
- High Performance Radiator (6mm fin spacing)
-GM Spal Brushless PWM Fan (4400+ CFM)
- Full Fan Shroud
- Bar and Plate Intercooler
- FJ40 Cooling package Mounts, Rubber isolated to allow for body flex,
and thermal expansion.
- Radiator and Intercooler cores are USA Made.

And, of course includes all the bracketry that you showed in the photo of them developing it.

I can buy a Mishimoto Intercooler or radiator from Summit for about $270 each, $200 if you go with house brand. Fan and shroud, $200 maybe? I get that they need to make money and stuff and development is a PITA (took about 3 weeks in their case I think following them on IG) But really? That's $4200 CAD!!! I can buy a brand new TIG machine and all the radiators and break even on that.