Troopy Rebuild Help Needed

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K

KLXTroopy

10 Year
Joined
Jan 31, 2014
Threads
5
Messages
12
Hello to all. My first post so go easy. I'm in the progress of building up a 99 HZJ75 troopy and I've ran into a few problems.


Number one is that I've got a 1hz out of an 80 series and bolted it up to a h55f gearbox. I dropped the engine and gearbox in as one last week and then I bolted the gearbox cross member onto the chassis. With the engine sitting firmly on its mounts and the gearbox sitting on its mount I cant seem to get the 4 bolts on the rubber gearbox mount to line up. It needs to be moved to the passenger side (Right Hand Drive) about 1cm more. At the moment, looking at the engine from the front it already looks like it is running diagonal enough to make me think that something might be wrong :confused:. The cross member is out of an Fj73 that had the coarse spline h55f gearbox. Is it possible that the older 70 series cross members are slightly different to the HZj75 ones.


The second problem is that the fuel cut solenoid on the engine has 3 wires, where the troopys fuel cut wiring from the wiring loom only offers 2 wires. I have tried different combinations to get the fuel solenoid to click but it won't. Is it possible that I am missing a fuel control relay or that my wiring is faulty somewhere.


If anyone could help me out with these two problems it would be much appreciated :beer:
 
Lift the weight off the mount with a jack
Adjust accordingly
Start bolts a few turns
Lower and tighten

Can't help with the electrical sorry
 
If the solenoid is the same size, maybe swap in a 2 wire switch and see if that works. Did you have a dead 1HZ in the truck you can poach parts from? IIRC the cut off is a couple hundred clams from the dealer.
 
Thanks for the replies. As for the gearbox mounting problem I've tried taking the weight off the mount and adjusting but the gearbox won't move enough. I'll give it another shot though because its slowly getting closer.
I haven't got a dead 1hz that I can get a 2 wire solenoid from. I'll try and get a engine electrical wiring diagram from a 80 series and work out why this solenoid has three wires. I always thought that they just had two wires.
 
I remember when I put a 1HZ into a FJ73 I had some difficulty getting the gearbox mounts to line up.
Some of the bolt holes for the rubber mount are elongated, I forget whether they are on the T/case or cross member.
But if you loosen them off it gives you a inch or so to play with.
I had a few cross members from a HZJ75,FJ73 and a HJ75 at one stage and I could not discern any difference when I laid them out next to each other.
Im pretty sure I used the FJ73 cross member as the other 2 came from mining vehicles and were fairly battered.
However when I finally got the 1HZ gearbox in ,the gear stick was still further to the RH side than the original coarse spine 5 sp
I also loosened the engine mounts off and tightened everything up when it was in.
I took measurements off a HZJ75 to make sure it sat in the engine bay the same.
But there is something different and I don't know what it is.

As to the wiring to the solenoid.I think the older 7* series had 2 wires while the 80 series had 3.The later 7*series and 105 series also had 3 wires.
I think the extra wire had something to do with an immobilzer.
I would 1st try a simple 12 volt connection to the solenoid to make it click to verify its working.
I plugged my solenoid into the wire that powered the solenoid on the carb on the old 3F,worked perfectly.
 
Thanks Rosco very helpful. I've loosened all the engine mounts and I'm using a new gearbox mount. I managed to get the gearbox to line up but the engine is running on a real bad angle and the engine is sitting off its two mounts because of the angle. Is it possible that my chassis is bent or that their is something wrong with my engine mounts? Does anyone have a crossmember out of a Hzj75 that they could measure up so i could compare it with mine just to eliminate it as the problem.
The pictures attached dont really show just how bad the angle is. The gearbox is currently just sitting on the cross member because there was way to much pressure/force on the engine and gearbox mounts. In the picture the gearbox needs to be moved about 1 inch further to the passenger side which would increase the angle. The straight edge is centred on the body. Any Ideas?

IMG_1289.webp


IMG_1290.webp
 
you are using the R151 cross member (original for the truck) to mount the H55?
or you found a HZJ75 pre 1998 H55 cross member to use?
 
80 series engine mount is totally different from a 70 series. You will have to source the 70 series engine mount.
An 80 series engine mount will result in what you're having now, tilted engine.:D
 
Crushers, I am using a cross member out of a Fj73 which should be the same as the Hzj75. The troopy originally came out with the 1hz and the h55f gearbox.
Wongtsenhin, the rubber blocks for the engine mounts are stock with the car so they aren't the problem. Are you talking about the steel arms that bolt onto the motor and the rubber blocks? To me this sounds like the most likely problem.
 
KLXTroopy said:
Crushers, I am using a cross member out of a Fj73 which should be the same as the Hzj75. The troopy originally came out with the 1hz and the h55f gearbox.
Wongtsenhin, the rubber blocks for the engine mounts are stock with the car so they aren't the problem. Are you talking about the steel arms that bolt onto the motor and the rubber blocks? To me this sounds like the most likely problem.
Click to expand...

I was at this frustration point when I transplanted my 1hdt using the 80 series engine mount into my chassis. With some misalignment, it still slotted in except tilted engine and some bull forces in order to do that.:D
Yes! Steel arm with 4 screws that bolted on the side of the block. You'll need both R & L hand arm for the engine to stand straight.:cool:
 
Thanks for the replies. I'll try and get my hands on some 75 series engine mounts and hopefully they will fix the problem.
 
Problem Solved. It was the gearbox cross member and the engine mounts. I just helped a mate take the engine and gearbox out of his 95 Hzj75 and I compared the engine mounts and cross member with mine. So they are definitely different. Thanks to all who replied and offered some help.
 
crushers said:
so it MIGHT depend on which tranny mount was used in the FJ73

just guessing now.
Click to expand...

I had 3 of them from FJ73,HJ75 and HZJ75 and the crossmembers and they all looked the same to me.
My son works in spare parts at a local shop ,Im pretty sure he told me all the leaf sprung models used the same gearbox mount when I needed one.
 
KLXTroopy said:
Problem Solved. It was the gearbox cross member and the engine mounts. I just helped a mate take the engine and gearbox out of his 95 Hzj75 and I compared the engine mounts and cross member with mine. So they are definitely different. Thanks to all who replied and offered some help.
Click to expand...

That's weird because I lined them all next to each other and mine were the same. I have some pics on my other computer, Ill try and post them when I get home.

Are you talking about the engine mounts or the engine mount brackets? They are different .You did weld new brackets on didn't you?
 
Rosco I'm talking about the cast brackets that bolt onto the engine block. I haven't welded any new brackets. Everything is stock.
As for the cross member I took the fj73 one to my mates place and when his cross member was out of his Hzj75 I compared them. They both bolted up exactly the same to the to the chassis but the two bolt holes for the rubber gearbox mount on his cross member were about am inch towards the drivers side.
At that moment I thought that that was my problem so I went to the wrecker last night and asked him if he had a cross member out of a Hzj75. I brought my Fj73 along just to make sure they were different. They were exactly the same. I told the wrecker my story and he said that their should be no difference in the cross members and that he had never heard of anything like what I was experiencing.
I helping my mate with his engine/gearbox tonight so I'll compare the cross members again. Maybe its time for glasses.
 
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