Project Questions

[Toshi38]

I'm considering a new project for when I get back to BC (Less then 2 weeks!)

I'm thinking I might buy an 83 BJ60 5spd and swap the engine/trans/transfer/axles into my 1975 FJ40 (3F, 4spd, Drum Brakes).

What I want to do:
3B/H55 into the 40
Spring over with 60 Axles


Things I know I have to worry about:

Engine/Trans mounts
Cross member
Holes in the floor for shifters
Drive Shaft Lengths
Wiring
Cut and Turn/spring perches
Fender Flares (Adding approx 4 inches by swapping to 60 axles)

Things I don't know:
Clutch/Brake masters (Do I need to swap these)
Steering Column Differences (non-PS to PS)
Wiring - How much do I need to change for the 3b from my original wiring for the 2F

Anyway I've been doing lots of reading on mud... and have a lot more to do but does anyone have any wise words of advice?

The plan right now is I would do this in stages:
1. Get the 60/Part it out
2. Put Engine/trans/transfer case into my 40
3. Do cut/turn/spring perches on the 60 axles
4. Mount axles/PS for spring over

Does any of this sound reasonable or am I insane?

 

[seapotato]

sounds like a busy weekend....


but naw, I did the same thing years ago. kindof wrapped it up into a frame off with a nice 42 frame I'd found and an aqualu tub.

Whole thing took about a month, working eves and weekends.

So nope, not insane...all pretty straight forward, especially with the 60 parts truck.

 

[Toshi38]

The weekend part would be parting out the 60... so my dad can't move it out of his yard easily... that's the vital first step! He's going away Sept long... so I could do it then before he realizes...

I have 2 weeks to kill before going away again. Seems like a good way to spend it...

If you did a similar thing do you remember any particular complications?

 

[seapotato]

If you did a similar thing do you remember any particular complications?

keeping enough beer around was difficult.

lifting the cowl onto the soa frame by me onesies wasn't much fun...

your rad will have the bottom port on the wrong side...

sometimes the rear tcase output and the frame crossmember want to occupy the same space...I think cut,twist,weld works for that...(tho I went for slice slice hammer...)

number one thing I've noticed about messing with trucks, when you part that 60, keep EVERY bolt you can find before getting rid of the carcass...you can never have enough.

 

[slowandsteady BJ]

keeping enough beer around was difficult.

lifting the cowl onto the soa frame by me onesies wasn't much fun...

your rad will have the bottom port on the wrong side...

sometimes the rear tcase output and the frame crossmember want to occupy the same space...I think cut,twist,weld works for that...(tho I went for slice slice hammer...)

number one thing I've noticed about messing with trucks, when you part that 60, keep EVERY bolt you can find before getting rid of the carcass...you can never have enough.

Yes keeping bolts is SO important. Living far from the nearest Lordco or whatever makes "one bolt trips" so irritating. Bolts are the one thing I admitttaly hoard.

Ill help you with the Cut and turn and we can mount perches as well. Get going on parts ordering asap. Buy perches from wherever... 7"ers are nice as they will help with axle wrap. Marlin seals, bearings and a knuckle service kit so its all ready to go. Also figure out your shock situation as the stockers won't work well at all.

Cam

 

[Toshi38]

for the rad can't I just use the one out of the 60 to put things on the right side? or will it not fit in the 40? Is there a better method?

Where did you get perches from before cam any good suggestions on that?

Also how good are the marlin seals compared to normal ones... from what I understand they're some sort of double seal?

Will I need shock mounts to weld onto the axle too?

So for the axle I'd be needing the following correct?
http://www.marlincrawler.com/axle/front-axle-parts/knuckle-service-kit-wheel-bearings
http://www.marlincrawler.com/axle/front-axle-parts/hd-inner-axle-seal-fj40-fj62

And for the rear:
http://www.marlincrawler.com/axle/rear-axle-parts/land-cruiser-rear-axle-rebuild-kit

What else should I consider doing at the same time? I'd like to get things done as right as possible the first time!

 

[seapotato]

I always just made perches with a hole saw and a chunk of rect tubing, but if they're cheap enough, I guess you could buy em. Dodge sold ones that work, but I think they're short...

for shock mounts, I just butt welded a bolt to a chunk of plate...worked for years...shocks are seriously over rated...

rad...I don't think the 60 rad will fit in there, it's wider than a 40. I made a 40 gasser rad work by making a crossover tube under neath on my old 45. it was ok, but a tad ghetto.

Couldn't tell you about all those fancy rebuild parts, I made sure to only use parts that were well seasoned and had a nice coating of grit on them.

 

[hellbent40]

so the plan is 60 axles under the 40...
you will have to outboard your spring hangers on the 40 frame to make the 60 axles work.. unless you plan on moving the spring perch into the diff

so your going to have some 60 parts for sale soon then...

 

[bikersmurf]

You could just drop your 40 tub on the 60 frame

 

[Toshi38]

You could just drop your 40 tub on the 60 frame

Its funny... this did come up when me and my buddy were discussing it... Perhaps it warrents a closer look?

I'd obviously have to shorten the 60 drive train and a whole bunch of other things any ideas what they'd be?

 

[Toshi38]

hmmm interesting:

https://forum.ih8mud.com/40-55-seri...w-put-60-series-axles-under-40-55-series.html

 

[Toshi38]

so your going to have some 60 parts for sale soon then...

Ya... because my dad's going to shoot me if I leave another truck on his lawn right after he threw out the other trucks I think the plan will be to just grab w/e I need/can in a hurry and junk/trade the rest... If there's anything on there that you need/want we can figure that out. Bit of a drive from you though!

If this all goes as planed I'll also have a 40 drive train (Good 2F, trans/tranny (seal between them is gone so it pumps fluid up into the tranny), and axles from the 40 (new fluid in them last fall)

 

[bikersmurf]

Its funny... this did come up when me and my buddy were discussing it... Perhaps it warrents a closer look?

I'd obviously have to shorten the 60 drive train and a whole bunch of other things any ideas what they'd be?

Or stretch your tub... Know any aluminum welders

Now would be the time if you wanted a longer wheel base "40".

 

[slowandsteady BJ]

for the rad can't I just use the one out of the 60 to put things on the right side? or will it not fit in the 40? Is there a better method?

Where did you get perches from before cam any good suggestions on that?

Also how good are the marlin seals compared to normal ones... from what I understand they're some sort of double seal?

Will I need shock mounts to weld onto the axle too?

So for the axle I'd be needing the following correct?
Knuckle Service Kit with Wheel Bearings | Marlin Crawler, Inc.
HD Inner Axle Seal, FJ40-FJ62 | Marlin Crawler, Inc.

And for the rear:
Land Cruiser Rear Axle Rebuild Kit | Marlin Crawler, Inc.

What else should I consider doing at the same time? I'd like to get things done as right as possible the first time!

I made my spring perches as ryan described, but for the price and considering your time frame order some. They are cheap.

Knuckle rebuild kit..... Isnt totally nessasary but I'd do it. They have to come apart for the C&T so throw in new parts while you're in there. Could skip this step minus the seals. New seals are a must as the old ones will die during the C&T welding process. Marlin seals are the way to go hands down.

Rear axle... Leave it alone if you like, just needs new perches.

Shocks and mounts. If you grab a Knuckle ball gusset kit lower front mounts will be part of that kit. All pro kit is better than Marlin but both are good. Upper front mounts - can't beat F250 shock towers. Rear lowers will come with Rancho 5000's at least mine did, just weld to axle housing. Rear uppers is a fab show, no big deal.

I got a little carried away with my S.O. and the bill was spendy but I replaced everything minus birf's. work out a budget and go from there.

If you are buying Marlin stuff locally (like NSOR) get what is in stock. If the retailer says they have to order the stuff from Marlin, look elsewhere. Marlin orders are backloged in my experience and the chances of getting it all in time is next to impossible. NSOR got me everything I needed fast. John at Radd is a good bet as well. My .02

 

[hellbent40]

trail gear also sells a ball gusset kit for the front end... creeper kit..

but there is an important piece that is being overlooked with your SOA ... high steer arms.. which is costly but a most if you go SOA

and for the rear i would recommend a track bar or anti axle wrap bar

as for spring perches and ubolts.. look at ruffstuff specialities

 

[Toshi38]

I made my spring perches as ryan described, but for the price and considering your time frame order some. They are cheap.

Dodge perch's are part # P4120074 but they're only about 5.75" or so not 7" but I guess a traction bar could solve axle wrap problems if I have them?

Knuckle rebuild kit..... Isnt totally nessasary but I'd do it
.... Marlin seals are the way to go hands down.

Do you know if Radd carries the marlin seals ? I know they had rebuild kits not sure if the price I was quoted included bearings or not? John any word on this?

Shocks and mounts. If you grab a Knuckle ball gusset kit lower front mounts will be part of that kit. All pro kit is better than Marlin but both are good.

This is to strenthen the axle correct? Also to provide shock mount...

Upper front mounts - can't beat F250 shock towers. Rear lowers will come with Rancho 5000's at least mine did, just weld to axle housing. Rear uppers is a fab show, no big deal.

Where did you buy your F250 Shock towers?

Man I'm glad you did this so recently!

 

[seapotato]

I got my shock towers from the ford dealership...think they were under 20 bucks a piece.

Kinda funny actually, went in there with the part number, but before I could even read it to him, he said, " you mean the toyota ones?"

 

[slowandsteady BJ]

but there is an important piece that is being overlooked with your SOA ... high steer arms.. which is costly but a most if you go SOA


Ahhh right you are Adam. I forgot that bit. Kinda important.

Oh and I ment "Trail Gear" instead of "All Pro"... the Trail Gear ball gusset things have a better lower shock mount design than the Marlin's IMO. (Ken thinks so too.... (he knows lots)) lol.

 

[crustyBJ60]

what about a sky mfg. wide kit for the 40 front? (less fab work, but will cost)

why not up grade to the non-ABS 80 master (1" bore) and be done with it.

what type of PS? mini or 60 or stock 40 or sag?

x2 on the ruffstuff gear... and you will need an anti-wrap bar for SOA.

spend some $$$ on your high steer set up. 4x4 labs make some nice stuff.

price a new ( or re-man. rad for a 3b 40) the outlets/inlets will be in the correct location and it'll be new. or maybe someone has a good one kicking around?

the wiring is not an impossible task, just takes a bit of time.

cost out a few different combinations of what you want to do, then shop around for what you need. prices will vary from vendor to vendor.

sounds like there are a few around to offer a hand/advice, you'll be able to do it right the first time.

cheers
crusty

ps. yes, i'm still looking for a "dimmer" headlight switch. i could use a pair of ford shock towers myself, if someone wanted to pick up a set and send them to me.

 

[Toshi38]

Crusty,

I'd be happy to drop a set off for you in sept. I'm still coming to Aus. I think I also have a headlight dimmer switch. 12V? I'll dig through my boxes when I get to courtenay.