Upgrades for the coming season

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Definite progress but a long way to go yet. I went to start it to test the bled brakes and got no juice. One battery at 2.5V and one at 9.5. Charged both up to 12.3 but the low one went back down to 11 something just sitting. My cheap Princess Auto battery tester shows 1000 amps on the good one and "BAD" on the other one. They are a year old and I recall a warranty so I'll take the bad one back tomorrow and get a new one. I buy all my alternators/starters/batteries at B&F Auto Electric and have for 25 years. They're no good for the 24V stuff but great for everything else.
 
Wow! Nice job. I'm not on the site much these days but love to stumble on stuff like this.


I know I'm late coming in and certainly not a purist by ANY stretch, but have you considered making a slightly taller fiberglass tranny hump for the 45 instead of cutting it? Brett and I have discussed this at length as a solution to cutting for alternate transmissions. If not, cut away!

Excellent thread.


:beer:
 
Dom!!


I don't think I mentioned it here in the thread but I won't be cutting the tranny access panel at all. Firstly, the shift tower I am using is one of the unobtainium original 40 series units with the forward shift lever so it theoretically should require no mod whatsoever to the tranny hump.

But - I am using an H55f from a BJ70 and there is the potential that the t-case shifter could be different. Add to that the fact I intend to use one of Georg's twin stick kits on this build.

The 79-84 tranny cover is quite simple so I had planned to make one from scratch and set the original aside.
 
I was ready to put the new drive train together for the swap after reorganizing the garage. I had to wash the truck first. It wasn't bad on the outside but under the hood there was a half inch of mud on everything. I let her dry overnight and collected the pieces. I found an issue right off the bat.

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I half expected this so was not too stressed. The aluminum 70 series bell housing is not the same pattern as the the flex plate I have from the 1983 BJ42 that the engine came from. Also, the starter mounting holes and obviously the starter are different as well. Behemoth60 here on mud supplied the donor transmission that the bell housing and t-case came from so I called him and he was able to give me the 70 series flex plate as well as a 24V starter - all from the same donor drive train.

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The starter sits a half hole higher but the center to center from starter to crank is the same. The 70 series starter mounting bolts are also a half hole further apart.
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Also, one hole is tapped and one is a through hole but they are reversed. That starter is the BJ42 unit.
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Proper flex plate and re-surfaced flywheel on.
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Make sure the pilot bearing fits well
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Together.

No pics but once I installed the 70 series starter I knew I could not use it. The motor on the 70's sticks out directly horizontal and would hit the steering box. So I drilled out the lower hole on the bell housing and used the BJ42 starter.
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Most hookups are plug and play as I swapped over the alternator/starter/EDIC from the other motor. I will be making a new exhaust manifold for the turbo and using a custom altered stock air filter housing.

 
You made that look friggin' easy. what's the story on the blue 40 series?
 
That one belongs to my brother. I am going to take the body off and fix the frame before cutting out all the rust. Then it's getting the 3B/H55f/Toybox/splitcase that is currently in the red 45 (it's just sitting in there, not installed in there).
 
That one belongs to my brother. I am going to take the body off and fix the frame before cutting out all the rust. Then it's getting the 3B/H55f/Toybox/splitcase that is currently in the red 45 (it's just sitting in there, not installed in there).


Nice work...

You are a brother most of us need..:)
 
Ok… update.

I’ve been working on the 42 during all of my free time since the last posts.

I had some nervous moments caused by unknown issues (at the time). My 5spd that I ran through the gears on the bench before mating to the 3B was jammed in neutral and would not shift in any direction. That meant I could not be sure the gears wouldn’t explode if I started the truck. The only thing I could do was pull the top plate off. But there is no way to get it off when the drive train is all bolted up in the chassis. So I dropped the cross member and lowered the t-case down until I could get the top cover off. Wasn’t to bad really.

Once I had the top cover in the vise it still would not shift. This was good because it meant the tranny itself was fine. I poked around in the internal shift slides and got it un-bound. The reverse fork was out of sequence. I dropped the top plate back on the tranny first try and she shifted just fine. Whew!

I got the twin stick setup installed with a new aluminum cover plate so I don’t have to cut the stock one. Thanks for the kit Georg.

I couldn’t start it up without batteries so I installed the towers and batts. I had to do the rad too so that went on. I had the typical leak when adding the coolant. When I swapped the EDIC over to the new engine I missed the water jacket plug directly under it. So I was pouring coolant in all proud of myself and had a sudden waterfall emanating from an unknown invisible source. If you’ve worked on a 3B in and around the EDIC you know there is very little room there. Just removing the EDIC to access the leaking hole was a job unto itself. Plugged and filled the coolant.

Then there was the engine oil. When I got this engine originally it had a 1-1/2” nut welded to the drain plug with a rubber sealing washer. Now I know why. There was a defect in the sealing surface and the mine mechanics used the giant nut to seal the drain. I filled and drained the oil three times before I got it to seal. Mostly. It still weeps but it will do for now.

So, I had oil, water, power….ah, fuel. I’ve never done this before on a diesel so I checked the manual. Prime and vent the air out of the fuel filter and crank ‘til she fires is all it said. So that’s what I did. But I didn’t want it to start. This engine was rebuilt four years ago and has not been cranked since. Only thing I could think of was to remove the EDIC arm and crack the lines at the injector. I wanted to try and pump some oil around before we had internal combustion if I could.

I climbed in the cab, clutch in, no glow and did two spins of about 10 seconds. The pressure gauge did rise right away so that was good. Back under the hood I could see some fuel had leaked out of all four loose lines. Time to go for broke. Tightened the lines, attached the EDIC arm. Clutch in, glow and spin. She spun for a few and then each cylinder caught in turn before she started pretty rough. Some after glow settled it down some but I was getting an exorbitant amount of white diesel smoke. I ran to the garage door opener to clear the air before I started fiddling with the throttle linkage with it still running. It was missing and shaking and after about a minute she just quit. I tried twice to get it to fire again without success. It was pretty late by this time and I had made some good progress so I called it a night.
 
The next day, while I was at work, I consulted the RMLCA mailing list for any guidance of where to start my diagnostics to get rid of the smoke. Several guys came back with the thought it could be timing. They suggested I advance the timing some and see what happens.

That night I did just that. I loosened the injector pump and rotated it toward the block (advancing the timing). I tried bleeding the fuel filter again and did get more air. I then tried to start it and she did fire but was still pumping tons of white smoke before dying again. So I went the other way with the timing and retarded it. Again, lotsa smoke and no long term stability idle-wise.

The next evening I was able to pick up my newly stretched and shrunk drive shafts (found a great new vendor here in Calgary BTW) so I could actually try and maybe drive the potential air out of the system. Really I just wanted to test the 5spd. So I started around the block with no issues other than hesitation and surging due to fuel. Then instead of turning left into the driveway I went right, to the highway. It seemed to be getting marginally better after a couple of kilometers so I turned around and went the other way on the divided hwy. If I drive past my turn off there is a hill and a turn around at the top. I figured I’d test the power on a hill before turning around and trying to set a land speed record on the way back down (I wanted to try 5th and couldn’t get there on level ground).

At the same time it was getting dark and I had apparently forgotten to plug my headlights back into the harness. So I stopped at the turn around and opened the hood to do that. She was idling quite nicely at first but as I plugged in the left turn signal she stumbled and stalled. Damn.

Let me back up the bus a second here. When I jumped in for the test drive I was kinda stoked. So stoked in fact that I did not grab a jacket. My garage was nice and toasty but the abient temp outside was -10°C. That’s ten degrees C below the freezing point of water for you ‘mericans. I also neglected to grab my cell phone. So here I was far enough away from warmth that I would not die of exposure but I would get damned cold without a hat if I walked back. I had no phone and a truck that may or may not start.
I neglected to mention above, one reason for it not starting just might have been the fuel gauge showing less than empty. Never mind fuel delivery, how about just having some.

I cranked it and it started, kinda. But it wouldn’t stay going. It felt and sounded like I had run out of fuel. Where I had stopped was between the East and West bound lanes of 22X, a divided highway with two lanes each way. This particular spot was a popular one for cyclist to park their cars before heading into the mountains to Bragg Creek and back, though not at this time of year. There were two cars in the small lot that were obviously parked there that day given the tracks in the snow. There was quite a bit of traffic in all directions but I was reluctant to give up hope. And I was reluctant to flag down a passing vehicle in the growing dark.

As I sat there contemplating my situation I noticed a car approaching from the West. The city was to the East of me and most traffic was coming from that direction so this one car caught my eye. As I watched it get closer it became a yellow VW bug. One of the new ones, not a classic. It slowed and turned into the road that linked the divided hwy and actually turned into the parking lot that I was partially blocking the entrance to. Great! They must have a phone I thought. I jumped out and as I rounded the back of the 42 I see there are two occupants and the passenger is holding what looks like a phone in what looks like the standard “taking a picture” position. She’s taking a picture of my truck!

I gave the driver a friendly little wave as I approached her window. She rolled it down and they began to explain that they had stopped to take a picture of my truck because the passenger was dating a guy that had one.

“He has a Swamp Donkey sticker on his too.” She said, referring to the club sticker Ratpuke gave me. “His name is Karl, he has a 40 Landcruiser.”

I immediately thought of Kroll who I thought was up in Edmonton. I had met him a while ago with Ratpuke.
“Do you know Charla?” she asked.

“Who doesn’t!” was my reply.

Anyway…. She was happy to lend me her phone so I could call my wife for a rescue but I am embarrassed to say I forgot her name. The girl in the car, not my wife.

Kinda cool to get help from a not-so-random passerby.
 
Could have been, I just can't recall. She and her friend were very helpful though.

There is more to the story. I'll continue.

My wife was on the way. The plan was to get some fuel and return. I used the starter to move the 42 into a stall and out of the way. As I was waiting there I started to think about whether I had actually run out of fuel. The gauge was low but I could swear that I had run it lower before. It dawned on me that in the dark and silence I could easily determine if there was any fuel in the tank by simply rocking the truck. So I opend the access door and twisted the cap off.

Flash back to last summer when Charla, Tyler, Coastal Kevin, Greg myself and others did the Whipsaw trail in BC. When we arrived in Princton my son and I stopped to top off the fuel. As per my custom, I set the fuel cap on the rear tire. My son closed the access door and handed me the keys and we lost the cap. I did the Whipsaw with a rag stuffed in the filler and bought another cap later at Canadian Tire. But all they had were non-venting caps.

Flash forward to the present and as I removed the cap and the tank inhaled in one massive swoosh I had an epiphany. I have been starving the engine of fuel!

I left the cap off, dug into my tool bag for a 10mm wrench and bled the air out of the fuel filter (though I'm not sure where the air keeps coming from). I climbed back in the cab and turned the key and after a few revolutions she fired up nicely.

My wife arrived a couple of minutes later and after a brief lecture about not leaving my phone at home she followed me back to the garage.
 
Here are a couple of pictures. The last couple of posts were out of character for me with no pics.

The twin-stick kit I got from Georg a few years ago.

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Front driveshaft. This is not the shaft that came off. I picked up a couple of 70 series shafts from a friend and will get them altered to fit.
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I made a new cover
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So the fuel cap was not the source of my fuelling issues. I have spent the last two days trying to find the source of air ingress into the fuel system. Bubbles make a diesel no-go. I have been posting in the diesel section for advice.
 
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