Builds Urban Assault Cruiser 92 FJ80 (1 Viewer)

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Rebuilding a transfer case at my leisure. Mine growls pretty bad. Got all new bearings and races and seal from toyota as well as new hardware.
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Fusible link color rating:

Pink30 amp
Green40 amps0.50mm²
Red50 amps0.69mm²
Yellow60 amps
Black80 amps1.25mm²
Blue100 amps



 
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Fuel pump is starting to go out. Installed a Supra pump. Its bigger than the old pump. Install went pretty easy until i realized the bad wiring. One nut on the pump is a 4mm thread, other is 5mm. Noticed dirt in the tank so I completely drained it and cleaned it out. Took it to the gas station to fill it up and dash started smoking. Previous shop wired the fuel pump to the circuit opening relay through ig1 circuit of the ignition switch. Fuel is one of the few circuits if not the last of the previous shops swap wiring I've not addressed. Ig1 can't handle the load in addition to the other circuits it powers. Ran a new wire from the alternator post, to a circuit breaker. Disabled the cor and pulled the old efi fan relay. Added new pins to the empty slot next to fan relay spot and wired to fuel pump red/green wire. Was going to use a new Chinese 40 amp relay I had, but after discussing with a relative decided a used Japanese relay is better and more reliable. Installed fan relay as a fuel pump relay. Drove truck around hard, but I was concerned with how small the red green wire is. It didn't get warm, but its only like 18 gauge or something. Cut off red/green wire and ran 12 gauge blue wire I had laying around to fuel tank pigtail in front or rear fender well which should reduce resistance in the circuit. I probably should run 12 gauge from the pigtail to the sender too. But I think it will be ok since it's not too long of wire. Old pump was dead silent, Supra pump I could hear slightly at idle. I added a insulation sleeve to the supra pump before installing.

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Replaced leaking steering pump. I think the reservoir was leaking through the rust. Deleted the evo valve which can cause problems. Installed a f150 tranny cooler as a steering cooler. It fits really nice between the frame rails and I tucked it up high. The arb vents also direct air in this area. Had to use 1/2" to 3/8" line adapters since the ford cooler uses 1/2 line. The cooler is about 25" long. Power steering pump is easy to replace on a LS. Pull a couple bracket bolts and the whole power steering pump/alternator bracket comes off with the alternator and pump. Then its serviceable on the bench.
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Finished wiring the supra fuel pump. 3fe fuel pump wires are around 18 gauge, in the tank they are even smaller. I wanted to see if I could connect a new wire to the insulated sender plate junction. I removed the silicone on the top and found it was contaminated with corrosion. I drilled it out and removed it. It's a type of cool insulated rivet. I still had some tank studs from radium engineering so I replaced it with that. Now the whole fuel pump circuit is 14 gauge wire.
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I've not been happy with my shifter setup. Cable bracket was mounted to the trans tunnel but it didnt work smoothly and was too tight of clearance. So I made a bracket that mounts on the tcase. Works much better. Only have mock up pics before i cleaned it up and painted.
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Evap monitor parameters...

No active system voltage DTCs


• The ignition voltage is between 10 volts and 18 volts.


• The barometric pressure is more than 75 kPa.


• The fuel level is between 15 percent and 85 percent of full capacity.


• The engine coolant temperature (ECT) is between 4°C (39°F) and 30°C (86°F).


• The intake air temperature (IAT) is between 4°C (39°F) and 30°C (86°F).


• The start up ECT and IAT are within 9°C (16°F) of each other.



Amazon product ASIN B00J2EZXP2

 
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Adding digital coolant temp gauge that fits in switch blank. Power for key on power jumped off of rear heater circuit. Gauge reads between 16 and 302 degrees range.
Added arb compressor switch. It gets acc power from power mirror circuit. And switch is next to power mirror switch. Also added a Delphi 10 pin plug for trailer brake switch wires.
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Finished wiring the supra fuel pump. 3fe fuel pump wires are around 18 gauge, in the tank they are even smaller. I wanted to see if I could connect a new wire to the insulated sender plate junction. I removed the silicone on the top and found it was contaminated with corrosion. I drilled it out and removed it. It's a type of cool insulated rivet. I still had some tank studs from radium engineering so I replaced it with that. Now the whole fuel pump circuit is 14 gauge wire. View attachment 2191061View attachment 2191062View attachment 2191063
Is that in tank loom PTFE or something?
 
Is that in tank loom PTFE or something?
I think the power wire to the pump is polyethylene lined in the tank and the ground wire in the tank is PVC insulated which I think both are supposed to be able to handle gasoline. Or should I go with something else? The sender wires are just whatever came with the sender I think.
 
I think the power wire to the pump is polyethylene lined in the tank and the ground wire in the tank is PVC insulated which I think both are supposed to be able to handle gasoline. Or should I go with something else? The sender wires are just whatever came with the sender I think.
I'm not sure if PVC will hold up. I've always used PTFE wire. I thought it was what you had to use.
 
I'm not sure if PVC will hold up. I've always used PTFE wire. I thought it was what you had to use.
Their was a thread on pirate that mentioned that. But I found a few sources that said pvc was ok. Like this...
If you got any good sources I would like to read more about it, but I didn't find a lot of info. Im no expert on wire insulation. Would like to be sure so it will last a long time. I also read that pvc wire cant handle a lot of flexing, such as in a door jamb.
 
Their was a thread on pirate that mentioned that. But I found a few sources that said pvc was ok. Like this...
If you got any good sources I would like to read more about it, but I didn't find a lot of info. Im no expert on wire insulation. Would like to be sure so it will last a long time. I also read that pvc wire cant handle a lot of flexing, such as in a door jamb.
I couldn’t find much info either so I just splurged on a little bit.

I was actually curious about the black corrugated loom. That’s what I’d be worried about melting. Not trying to make you paranoid, I swear. Was just wondering.
 
I couldn’t find much info either so I just splurged on a little bit.

I was actually curious about the black corrugated loom. That’s what I’d be worried about melting. Not trying to make you paranoid, I swear. Was just wondering.
No I appreciate the concern, its gasoline so should be taken seriously. The loom is supposed to be polyethylene so hopefully it will hold up.


Took a drive up to Eisenhower tunnel. With the stock 5.3 and a tune pushing it hard she'll do 80mph up to the top. At high elevation like this regularly I could see wanting more power. But I don't go up this high everyday...and I'm sick of spending time and money on mods. Time to mostly just dial stuff in a bit and enjoy the ride. I'm curious how it will do pulling my camper or my 40 on a dolley up here. Also my fan clutch is acting up. It doesn't spin up well at lower rpms, and spins up like crazy at higher speed rpms. Which it wasn't doing before. She gets warm at idle with the ac on so have to keep an eye on it. The fan clutch should be under warranty.

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Got my transmission temperature gauge all wired up. Fits great in the oem switch blank. Also picked up a pop up camper.
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Ac idle up information,...

 
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I've been really sick for 2 months with the Corona virus. Really hit me on March 27th. Today I thought I would test myself and do some light work on my truck for a few hours. I installed a arb compressor under the cruise control. Dont have a pic of the airline kit installed. But I figured on board air comes in handy. I would like to add a air tank too eventually. I think I have enough room on the bracket to add another auxiliary fuse/relay box on the bracket too if I need it. Also been seeing a ton of built 80s driving around lately. I wave and they never wave back, oh well.:(
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