Rebuild 74 FJ40 RHD from Down Under - 2F to 2H to 12HT - 40 series Axles with 80 series Coils

[watrob]

Hey Rob, I read and re read your thread, an amazing inspiration to us all..

I have a question, In your first post you say, "1983 rear full floating hub with diff so I can install Hilux disc brakes with solid rotors". Do I read this right? In your rear disc conversion, are you using the Hilux front disc rotor (solid) calipers and caliper brackets from a '84 Hilux?? The question relates mainly to the caliper brackets..
I have '82 BJ40 axles and brakes under my old '73 40.

If so, theres a '94 down at our local Pic a part. I will shoot down and grab the bits..

Thanks in advance..

Gaz....

Yes you can use Hilux caliper's (1983 -1989), excepts solid rotor only DR154, pads are DB288, pads are the same pads as for the front discs on your 40. Front disc's are DR151 ventilated. These caliper's look the same as the fronts - 4 pots, except the caliper only excepts the DR154 solid rotor as it has a narrow gap.

It looks the same as your front calipers (except for the rotor gap). Bolt pattern is 90mm same as the fronts. The pots are the same as the front calipers, so parts are easy for rebuilds, same spring clips, same pads, These caliper's are on eBay as well.'

Brackets are easy to make out of steel, to get the final couple of mm use a washer as spacer on the caliper to centre the rotor?

 

[watrob]

Yeah why is it so much longer?

I think they packed a 60 series axle in a 40 series box? as it is way to long?

 

[watrob]

Joined the 75 series bell housing to my reconditioned 5 speed transmission, added a stainless steel disc rotor for hand brake and connected the t-case linkages.

 

[watrob]

Installed the rear Lokka diff, can now install the rear axles.

 

[Ol'40]

Rob, thanks for your answer and part numbers, much appreciated.. I hate to be a pain in the neck, but is there a design or a template to have the brackets laser cut??

Thanks again..

Gaz.....

 

[cruisermatt]

That transmission/t-case sure is pretty.

Axles: in order from shortest to longest:

40 60 80

Do you have 80 axles or just suspension?

 

[watrob]

That transmission/t-case sure is pretty.

Axles: in order from shortest to longest:

40 60 80

Do you have 80 axles or just suspension?

Just the suspension, looks like they sent me a 60 series axle by mistake?

 

[cruisermatt]

That looks like a 60 or early 80 axle shaft to me.

 

[Ol'40]

Sorry Rob, re reading your thread I see you got the rear disc brackets from Eureka 4x4...

 

[watrob]

Sorry Rob, re reading your thread I see you got the rear disc brackets from Eureka 4x4...

Yes, this is the second set I have bought over the years, you would think I would just trace a copy and cut them out myself but I give credit where credit is due. There well engineered and I make up in cost by buying the second hand Hilux caliper's which are cheap, easy to recondition yourself as are the brake pads. I run two complete chassis now so most of my hard work is done.

When I swap this new chassis in I will just rebuild the old one over the next 7 years as a hobby as it has all the correct parts.

 

[watrob]

Finally got the right front LH axles.

 

[watrob]

I am using a late model hj47/45 series transmission bracket, but because I am using a 5 speed out of a 75 series ( the added length) tends to cause the transmission to hang down a little. This causes a ripple effect to the front of the engine where the fan to the radiator is not even ( the rear of the engine is to low).

So I am going to use a 60/75 series gearbox rubber mount and add spacers between to lift the rear of the engine up?

 

[Efjay]

Hey Rob,

Just thought I better mention this incase you weren't aware.

You mentioned you are using a HJ75 bellhousing. I found the link below when doing my 12HT conversion. It shows that using a HJ75 BH slightly rotates the gearbox to the right (compared to a HJ47 BH) causing the transfer case to hang down lower. It can also cause clearance issues between the front driveshaft and crossmember. The photos in thread #62 shows the differences between the two BHs.

https://forum.ih8mud.com/threads/old-yella-gets-a-5th-gear.302432/page-4

Here is a shot of mine showing the rib position on a HJ47 BH.

 

[watrob]

The 70 or 60 series BH are the same (my previous build I used the same BH then, check page 2 post #21 of this tread). When you use HJ47 engine block mounts on a 2H or 12HT and place it in a FJ40 (petrol) chassis it kicks the engine anti-clockwise (which actually levels the engine). Also it lifts the front of the engine higher in the chassis which means the back of the 5 speed (and 4 speed) hangs lower.

Not sure if you used original 60 series 2H / 12Ht engine block mounts that came bolted on the engine block when you bought it or did you source HJ47 ones with matching engine to chassis rubber mount/pads?

On this build I am lifting up the rear of the 5 speed by 1" by adding spacers under the gearbox mount and also using the matching 60/75 series gearbox rubber mount.

Also if you look closely at the "old-yella" thread you will see that the gearbox is actually now kicked anti clock wise so the t-case level fits properly, it well might fit in but the later model 2H's and 12Ht were coupled to 60 & 75 series BH and not hj47 ones.

And finally I like the later model clutch fork (60/75 series) & clutch slave cylinder.

PS. and another reason why old-yella's t-case lever was hitting is because he was using a 4 speed lever which bends to the right instead of the 5 speed t-case lever which bends to the left (check my photo above)

 

[Efjay]

Sorry Rob........just trying to get my head around this.

"old-yella" is using the original 2H block with original HJ47 engine mounts, yet when he tried to use the HJ75 BH it twisted the gearbox clockwise on the gearbox mounts. What I can't work out is how that is different to your setup, but yours fits????? What am I missing here??? Is the transfer case axial orientation diferent between a 5 speed and 4 speed? I am assuming the engine mounts on the chassis are the same on FJ40 and HJ47.

I used HJ47 BH, HJ47 engine block brackets and HJ47 rubber engine mounts and it all seems to sit squarely in place.

Sorry to go on about this, just trying to work out where the difference is.

Many thanks for your advice and input on this, it is much appreciated.

Looking forward to following the rest of your build.

 

[watrob]

Finished installing the front axles, knuckles & hubs, plus front shocks and disc brakes.

 

[watrob]

Also finished rear axle install, hub & disc brakes, shocks attached. The chassis is still jacked up so there is no weight on the suspension yet.

 

[chappohj47]

It's close to being back together now mate did you work out the throttle dampner as I would like to see what you have done as I have just bought a 75series ute with a 12ht in it

 

[watrob]

OK got the gearbox & engine installed, still have to attached the gearbox cross member yet?

 

[watrob]

It's close to being back together now mate did you work out the throttle dampner as I would like to see what you have done as I have just bought a 75series ute with a 12ht in it

I have it but have not installed it yet.