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- #401
@cruisermatt see you in about three hours
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Build The Monkey is Back
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- #402
Ohhhhhhhhhh yeah
Post all the pics of the process you want @cruisermatt
Post all the pics of the process you want @cruisermatt
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Step 1.
We knew ahead of time the transfer lever would be a big issue with the RHD handbrake and I didn’t think I had a good shot at tracking down a actual RHD h55f transfer lever assembly.
Mocking up HZJ79 R151f shifter assembly (all parts available new). Measuring that it should easily clear the handbrake as-is and of course works perfectly on the transfer case going in (which is HZJ79-application). Normally we change the longer 79-specific 4wd shift rod to the 40/60 series version but in this case it works in our favor as is.
Just need a custom shift gate/support since this assembly is not meant for H55f. Fortunately we have full time engineering staff and a 3D printer to very quickly and efficiently design and make those 1-off parts.
We knew ahead of time the transfer lever would be a big issue with the RHD handbrake and I didn’t think I had a good shot at tracking down a actual RHD h55f transfer lever assembly.
Mocking up HZJ79 R151f shifter assembly (all parts available new). Measuring that it should easily clear the handbrake as-is and of course works perfectly on the transfer case going in (which is HZJ79-application). Normally we change the longer 79-specific 4wd shift rod to the 40/60 series version but in this case it works in our favor as is.
Just need a custom shift gate/support since this assembly is not meant for H55f. Fortunately we have full time engineering staff and a 3D printer to very quickly and efficiently design and make those 1-off parts.
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I show the RHD and LHD using the shift linkage for 40 series with a H55F. Believe this is a 60 series shifter from the US 5/85-8/87.
This is a transfer case shifter for a Australian 40 series with a H55F.
Been seven or eight years since I collected different shifters. Not sure if the one on the right is the same lever you are using.
Looking from the from the 70 series is a little further away from the transmission.
40 series
70 series
I also have a couple different 70 shifters. They are the two piece style but was able to get the shifter located in the same place as the four speed.
This is a transfer case shifter for a Australian 40 series with a H55F.
Been seven or eight years since I collected different shifters. Not sure if the one on the right is the same lever you are using.
Looking from the from the 70 series is a little further away from the transmission.
40 series
70 series
I also have a couple different 70 shifters. They are the two piece style but was able to get the shifter located in the same place as the four speed.
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Yep, that would be great to have but the owner tasked me with dealing with it and I don't really have time to hunt things like that down when we have a tight shop schedule and are fully capable of making other OEM parts work very well or maybe better in a matter of days. Very different as a business vs a hobby.
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Step 1.1 Initial inspection and notes.
Normally when we do involved projects at my shop we try and arrange for a vehicle inspection beforehand to make sure the owner's requests and description of the vehicle/project are realistic and accurate, confirm diagnostic of problems, and to spot any additonal potential hangups or issues that should be addressed at the same time.
Sometimes an in-person inspection is not possible for whatever reason, in the case of this project we didn't really have a good reason not to since Josh is relatively close but this project scope was large enough that it actually becomes less important since we are already planning on addressing basically everything, so there isn't much left to be a surprise.
That being said, since we havne't actually put eyes on it until it was delivered we do make it a standard to go over in detail as soon as it arrives to make note of anything we didn't plan for.
the only parts I was really concered about with this project were:
- the right side of the engine bay being very cluttered with the AC compressor, oil cooler, 105 steering box/shaft, and various hoses/lines
- transfer case shifter/E-brake handle (should be solved, see above)
- existing OEM PS pump compatibility with OEM AC comprssor, and if we needed to change pump, available of replacement unit or feasability to change to 3FE pump
Some of the things my eyes go right to. Fortunately as said we already have plans to address most of this.
Normally when we do involved projects at my shop we try and arrange for a vehicle inspection beforehand to make sure the owner's requests and description of the vehicle/project are realistic and accurate, confirm diagnostic of problems, and to spot any additonal potential hangups or issues that should be addressed at the same time.
Sometimes an in-person inspection is not possible for whatever reason, in the case of this project we didn't really have a good reason not to since Josh is relatively close but this project scope was large enough that it actually becomes less important since we are already planning on addressing basically everything, so there isn't much left to be a surprise.
That being said, since we havne't actually put eyes on it until it was delivered we do make it a standard to go over in detail as soon as it arrives to make note of anything we didn't plan for.
the only parts I was really concered about with this project were:
- the right side of the engine bay being very cluttered with the AC compressor, oil cooler, 105 steering box/shaft, and various hoses/lines
- transfer case shifter/E-brake handle (should be solved, see above)
- existing OEM PS pump compatibility with OEM AC comprssor, and if we needed to change pump, available of replacement unit or feasability to change to 3FE pump
Some of the things my eyes go right to. Fortunately as said we already have plans to address most of this.
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Looking back through the thread I don't think Josh actually posted the full scope of what we have planned for the "Spa session". In case anyone is wondering why this sort of thing gets planned 6-8 months in advance, here is the full list of what we are planning on doing and already have parts purchased/allocated for.
This is just off the top of my head, I think there are some small details but this is the main big things. Basically the goal here is for it to leave with the mechanicals 100% sorted.
1. Replace engine assy. with good running takeout from FJ60 that got V8 swapped (See Falcor )
2. Change Air filter housing assy. to USA 81-87 2F
2. Install AC (Nosalgic Air RHD specific kit)
3. Upgrade alternator to 3F
4. Change bellhousing to correct 2F version (currently has 3F bellhousing which puts unneeded strain on engine/transmission mounts)
5. Replace H55f/transfer assy. with new units
6. Replace transfer shift assembly to clear E-brake lever without mods
7. Re do transmission tunnel cover and shift boots to accomodate H55f
8. Convert steering to 80/105 Steering box
9. Replumb entire vehicle's brake and clutch lines with new stainless tubing/fittings
10. New Brake booster/Master cylinder
11. Rebuild front knuckles/brakes, replace locking hubs
12. Rebuild rear differential with Harrop E-locker, Inspect rear brakes/hubs repair as needed
13. Install full Terrain Tamer parabolic suspension kit
This is just off the top of my head, I think there are some small details but this is the main big things. Basically the goal here is for it to leave with the mechanicals 100% sorted.
1. Replace engine assy. with good running takeout from FJ60 that got V8 swapped (See Falcor )
2. Change Air filter housing assy. to USA 81-87 2F
2. Install AC (Nosalgic Air RHD specific kit)
3. Upgrade alternator to 3F
4. Change bellhousing to correct 2F version (currently has 3F bellhousing which puts unneeded strain on engine/transmission mounts)
5. Replace H55f/transfer assy. with new units
6. Replace transfer shift assembly to clear E-brake lever without mods
7. Re do transmission tunnel cover and shift boots to accomodate H55f
8. Convert steering to 80/105 Steering box
9. Replumb entire vehicle's brake and clutch lines with new stainless tubing/fittings
10. New Brake booster/Master cylinder
11. Rebuild front knuckles/brakes, replace locking hubs
12. Rebuild rear differential with Harrop E-locker, Inspect rear brakes/hubs repair as needed
13. Install full Terrain Tamer parabolic suspension kit
- Thread starter
- #408
I will chase the Third World out of this poor rig if it kills me.
I've sold the power steering box to @matt tin but the H55f/transfer case is still available (without shifter cane and whatever parts for the transfer case shifter linkage @cruisermatt needs). $1,000 plus shipping. Both shift well with no scary noises, but leaks like a sieve and will need going through.
I'll post this in the classifieds once it's out.
I've sold the power steering box to @matt tin but the H55f/transfer case is still available (without shifter cane and whatever parts for the transfer case shifter linkage @cruisermatt needs). $1,000 plus shipping. Both shift well with no scary noises, but leaks like a sieve and will need going through.
I'll post this in the classifieds once it's out.
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We can easily palletize and handle shipping as well.
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Custom transfer gate bracket/brace coming right up. 3D print to test fitment first before ordering from laser
We were also going to have to either find a OEM AC tensioner brace or reverse engineer one, and I was also hesitant to risk the brand new OEM steering box with his old steering pump so we decided to going to a new OEM 3FE pump.. not only new but a better design pump that will last longer due to the upgraded bearings. So we needed a custom bracket for holding the 2F Ac Slider off the 3F PS pump bracket.
We were also going to have to either find a OEM AC tensioner brace or reverse engineer one, and I was also hesitant to risk the brand new OEM steering box with his old steering pump so we decided to going to a new OEM 3FE pump.. not only new but a better design pump that will last longer due to the upgraded bearings. So we needed a custom bracket for holding the 2F Ac Slider off the 3F PS pump bracket.
Matt, this is some great skill and talent!! You would have very few issues with those Chinese bodies
EDIT: ok, you’d have some issues ..BUT, you’d resolve them !!
EDIT: ok, you’d have some issues ..BUT, you’d resolve them !!
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- #412
Wow. Beats my 'cut, grind, vice, hammer, fit, repeat' method.
On my LX and my 47 I trimmed the bracket so I could use 2WD low. But not sure it was strictly kosher.
Anyone else tried this?
On my LX and my 47 I trimmed the bracket so I could use 2WD low. But not sure it was strictly kosher.
Anyone else tried this?
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We have worked with the chinese parts a bit.. they definietely recquire some effort to be usable
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- #414
I like what you did with the customer's left side roof curtain in your shop using the Chinesium parts. Very industrious and turned out great.
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3D printed mockup.. printer is invaluable for this stuff. Parts are almost always correct on the first try now.
Also, just in case anyone was interested this is what the actual non-US 2F OEM AC bracket looks like on a Saudi 40 that’s here for some work (third pic). The problem with just making this is the pump bracket would still be wrong for the 3F style pump.
Will post side by side comparisons of the non-US 2F and 3F pump brackets when it’s apart since there’s basically zero pics on the internet I could find of any of this stuff, most of the cars owners that got these parts from Toyota were busy working and not posting on forums all day as a hobby
Also, just in case anyone was interested this is what the actual non-US 2F OEM AC bracket looks like on a Saudi 40 that’s here for some work (third pic). The problem with just making this is the pump bracket would still be wrong for the 3F style pump.
Will post side by side comparisons of the non-US 2F and 3F pump brackets when it’s apart since there’s basically zero pics on the internet I could find of any of this stuff, most of the cars owners that got these parts from Toyota were busy working and not posting on forums all day as a hobby
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I logged on today for the first time in what feels like several years. I bought my current 40 in 2012 with high expectations of rekindling my original ownership experience from 1990 while in college. I landed on Chamba's thread and have been here for over an hour. It has been a much needed boost of inspiration to get mine back on the road.
While sitting with a fellow 40 owner on Monday, enjoying a cigar, we talked at length about the joy I am missing while harboring unrealistic dreams. At ~60 years old and a meager budget, it is time to put it back together within my means and experience the joy these vehicles bring. My original 40 was a 4/70 FST (original soft-top long gone). This one is a 10/69, which I believe is also a 1970 year model? If I start a thread, the theme will be: Enough is enough, patch it together and enjoy the road with your children and grandchildren. They have looked at it sitting still long enough.
Godspeed to all,
Russ
While sitting with a fellow 40 owner on Monday, enjoying a cigar, we talked at length about the joy I am missing while harboring unrealistic dreams. At ~60 years old and a meager budget, it is time to put it back together within my means and experience the joy these vehicles bring. My original 40 was a 4/70 FST (original soft-top long gone). This one is a 10/69, which I believe is also a 1970 year model? If I start a thread, the theme will be: Enough is enough, patch it together and enjoy the road with your children and grandchildren. They have looked at it sitting still long enough.
Godspeed to all,
Russ
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- #417
Welcome Russ @Cruiserless ,
Amen to bringing them back on the road and enjoying them with family.
And cheers to discussing them with cigars and friends. I hope we get to do just that one day. I always wanted a '69 40: born the same year I was.
Please start that thread and may you fill it with great progress.
Amen to bringing them back on the road and enjoying them with family.
And cheers to discussing them with cigars and friends. I hope we get to do just that one day. I always wanted a '69 40: born the same year I was.
Please start that thread and may you fill it with great progress.
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Ditcherman
SILVER Star
Exactly.
I’m struggling with a 240Z project right now, with those big ideas and dreams, and the guy who sold it to me, who said it didn’t need hardly anything, gave me some good advice…make it a car again. Just make it a car again.
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Replacement 2F getting ready for some fresh paint before install.
And shift gate bracket and AC bracket in from laser.
Another note, I was crawling under the car to look at something and noticed it doesn’t actually have a 3F bellhousing like I thought, just a 3F lower cover jammed onto a 2F bellhousing. So that is slightly reassuring.
And shift gate bracket and AC bracket in from laser.
Another note, I was crawling under the car to look at something and noticed it doesn’t actually have a 3F bellhousing like I thought, just a 3F lower cover jammed onto a 2F bellhousing. So that is slightly reassuring.