Build Stretched 1-Ton FJ40

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Mike Shull said:
After the guys at the transmission shop learned about what I was running the transmission in, they told me that they wouldn’t run the aluminum tail housing and they recommended the same cast-iron housing. Although they had a cast-iron one in the shop that was also broken, it came out of a fleet vehicle and he said it was the first cast-iron one that he had seen broken. I might as well get a cast iron one coming while I’m here.
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While I was looking for that link I ran across them for <100$ on eBay. TK says they have seen a lot of problems with the import ones being out of tolerance. Not sure if it’s sales talk or true but I went that way.
 
Mike Shull said:
After the guys at the transmission shop learned about what I was running the transmission in, they told me that they wouldn’t run the aluminum tail housing and they recommended the same cast-iron housing. Although they had a cast-iron one in the shop that was also broken, it came out of a fleet vehicle and he said it was the first cast-iron one that he had seen broken. I might as well get a cast iron one coming while I’m here.
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Wait till I send the the video of you doing smoky burnouts
 
My driveline connection closed their business last week, and right in the middle of making my front shaft. I ordered a carrier bearing from Busted Knuckle Off Road and took the pieces over to Rocky Mountain Driveline in Arvada, CO. Blake has been in business for 20 years and this is his first intermediate shaft for a front driveline. It’s an experiment but it looks good to me.

My transfer case u-joint angle is sitting at 10° downward, the center u-joint is down from there another 5° and the front pinion u-joint is up approximately 4°. I only had to rotate my transfer case one notch downward and it still sets above my cross member. I’m pretty happy. I’ll make the carrier bearing mount this coming weekend and move on to other things.

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Mike Shull said:
My driveline connection closed their business last week, and right in the middle of making my front shaft. I ordered a carrier bearing from Busted Knuckle Off Road and took the pieces over to Rocky Mountain Driveline in Arvada, CO. Blake has been in business for 20 years and this is his first intermediate shaft for a front driveline. It’s an experiment but it looks good to me.

My transfer case u-joint angle is sitting at 10° downward, the center u-joint is down from there another 5° and the front pinion u-joint is up approximately 4°. I only had to rotate my transfer case one notch downward and it still sets above my cross member. I’m pretty happy. I’ll make the carrier bearing mount this coming weekend and move on to other things.

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Boy does this look familiar
 
I haven’t taken many pictures because it’s hard to get any good captures under the Cruiser, and quite frankly I am ready to crawl out from under this thing to work on something in the daylight so I have just been going strong.

My cast iron tail housing came and it adds at least another 25 pounds to this truck! It is stout. Thanks for the recommendation , @Ditcherman! The other one would not have lasted.

I’ve been etching away at the Cruiser after work and I got the new tail housing installed. I’ll get the transfer case back in place tonight, then bend a piece of tube for the carrier bearing mount. Once that is done I will assemble the rest of the undercarriage. While I am in here I will increase the parking brake leverage and button up a few loose ends, hopefully all before the end of the weekend.
 
Are you running an FJ40 clutch master and slave, or dodge parts or what?
I am re-re making my dodge master adapter to the firewall and questioning if there’s an easier way.
 
Ditcherman said:
Are you running an FJ40 clutch master and slave, or dodge parts or what?
I am re-re making my dodge master adapter to the firewall and questioning if there’s an easier way.
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I am running the factory clutch master and slave cylinder with an AA bracket. You will need a short throw clutch for to work with this setup.
 
my front driveline is in and I am happy with how it looks. Hopefully I can test drive it tomorrow. I need to get the fuel and electric lines back in and bleed the brakes…and a dozen small items.

if you look close at the carrier bearing mount you will see where I messed up and cut too much material out with the plasma. Oops. I must have got the metal way too hot in the process as I heard it move when I was welding it together. It moved nearly 1/2”!

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Gosh dang, way to go AA 🙄

If you have any, I’ve had WAY better luck sealing cases and what not with Toyota FIPG than any other gasket maker. Loctite anaerobic stuff would take 2nd place
 
Back to the drawing board. This piece tweaked a bit when I welded it together and I popped one of the bolt threads in a hard to reach area trying to suck the bracket to the frame.

I probably need to sell the welder. There must be something wrong with it given that this is the second time in a row that I had this happen. Don’t do this. Take your time and watch your heat!

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Broski said:
I don’t think it’s you welder.
Things need to be welded in a jig, should be welded slowly and checked constantly.
I’m guessing you know all of this.

I hopefully that you bring this to Sand Hollow in April 😎
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It’s definitely my welder…it has gotten very old and somewhat delusional, and half of the time he can barely remember what he was working on.

April might be pushing it a bit but I do want to check out that area.
 
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