Prado (KZJ78) PTO mid mount winch

[kbushnz]

Hi All...
Started my next mod..
Mid mount PTO winch in the LWB Prado...
Fitted the PTO gear in the transfer case over the weekend.
And also given the PTO unit a birthday with new bearings and seals.
Also reversed the output drive from front to rear.
You need to adjust the spacer on the shaft as the gear is in the wrong place when swapped end for end. Needs to have 1/4 inch removed and then another 1/4 inch spacer made. (give or take)
Next is working out the levers as mine is auto and there is no provision for the brackets..
Then Mounting the winch itself.
Its had a birthday also, new seals and some minor bending of bits back into shape.
Some parts are getting nickel plated (just cause I can)
Will post photo's later in the week.
Now that I can attach the PTO unit, I can work out the rope run for the winch.

Nows here where I could do with some help..
Anyone out there with photo's of what they have done or not..
And cause why will help.
I think I can get it on a straight run from the front to just past the transfer-case then a slight direction change to the winch.

Plan to drive the winch with a CV drive shaft from a small FWD car...

Calvin

[meatc]

Main hint - keep as much room as you can between the drum and the first guide, and keep the drum centred and square to the rope. In reality you need at least 800mm more if you can. They spool flat under load but may peak in the centre when slack.

Mine runs through a peice of rollcage tube with 2 bends in it, works mint and hasn't casues any issues with rope.

[mudlva]

head over to papakura and have a look at my set up bring a camara as well it you want

[kbushnz]

head over to papakura and have a look at my set up bring a camara as well it you want

True, I can grab some shots when I collect the Welders...

Calvin

[Sadam_Husain]

theres a simular setup mid mount cruiser winch on a zuk jimny here http://www.offroadexpress.co.nz/Forums/ ... 18&t=11924

[kbushnz]

theres a simular setup mid mount cruiser winch on a zuk jimny here http://www.offroadexpress.co.nz/Forums/ ... 18&t=11924

Thanks for that, I have done the search and google bit and seen a few setups, Looked at Gertrude, Andrew Farmers I think, Bruce Hughes's and some others from over the ditch... Also the one you refer.

Thats similar to what I want to do, however I don't have the luxury of making the body fit and clear after the fact....

My main concern is rope routing so as not to stuff the rope or have issues with it not laying properly.

Calvin

[mudlva]

head over to papakura and have a look at my set up bring a camara as well it you want

True, I can grab some shots when I collect the Welders...

Calvin

yea sweet as

[kbushnz]

Here are some photo's
Transfercase all put back together.
I didn't use a new gasket between the cases, this caused the preload on the output bearing to increase, just used another gasket to pack it out.
Idler shaft clearance still in spec.


Next is the PTO gear inside the transfercase.


Now here is the PTO unit, with output now facing the rear.
Can't see the spacer but if you don't adjust it the gear moves too far rearward.




Here is where the winch is going to go, somewhere up there.
Have heaps of room now that there is no muffler !


And finally somewhere up there will run the cable... You might be able to make out the string line..


Will add more as I go along...Have to work out how to do the lever for the PTO as the auto has no bolt locations at hand unlike the manual.

Calvin

[mudlva]

nice similar to my set up indeed

re the pto lever have a push pull cable made, as i went to a solid mount to the floor tunnel and its an issue. when the body flexes it moves the lever around and noises start as the teeth grind past each other. this wont be at issue with a cable

[jeremy]

re the pto lever have a push pull cable made, as i went to a solid mount to the floor tunnel and its an issue. when the body flexes it moves the lever around and noises start as the teeth grind past each other. this wont be at issue with a cable

Any suggestions as to where to get a decent push pull cable from?

(sorry for the little hijack Calvin)

[mudlva]

re the pto lever have a push pull cable made, as i went to a solid mount to the floor tunnel and its an issue. when the body flexes it moves the lever around and noises start as the teeth grind past each other. this wont be at issue with a cable

Any suggestions as to where to get a decent push pull cable from?

(sorry for the little hijack Calvin)

Hi Jemery

i was told to go and see the chaps in the auto parts shop in tainui rd (where the roundabout is) as they could make a cable to suit.
so far ive been doing other stuff but its on the "to do" list at some stage

it will need to be grunty
also think of the marine trade, there is push pull systems for outboards, rudders etc

a marine system would be made to handle the crap that we throw at our trucks as well

[jeremy]

thanks Rohan, I'll have to look into it.

[kbushnz]

a marine system would be made to handle the crap that we throw at our trucks as well

I was looking at that also, but for the free spool....

When I get to that stage...

Calvin

[kbushnz]

OK Guys need some assistance.
I need to mount the PTO lever but there is no provision on the auto to mount it.
Unlike the manual (like Mudmike's below)
The auto doesnt have any locations.
I have an idea but wanted to see what others might have done.


Calvin

[darinz]

Any suggestions as to where to get a decent push pull cable from?

(sorry for the little hijack Calvin)

Gear shift cable from front wheel drive car is what I used on my winch for the freespool.

[monstr]

Hi Calvin how long does it need to be ,i have a spare Nissan pto cable that might work if you want to try it ,also have the pto control/selector if wanted.

[kbushnz]

Hi Calvin how long does it need to be ,i have a spare Nissan pto cable that might work if you want to try it ,also have the pto control/selector if wanted.

Thanks for the offer Steve...But have found a solution.

Have taken the plunge today (Monday) as the weather outside is nice, and there is no room in my garage for a truck and welding.
So set up table outside and set to make the lever fit.
Used boot and mount for a template and cut hole in floor / tunnel.
Then utilizing the two lower holes for mounting the boot, ground down top flange on bracket and welded on some nuts. This means there will be no extra holes thru the tunnel....
Then bent the lower part of the bracket to fit snug under the floor.
This happened to align with the speedo mount. So just broke it off and used the spot weld hole.
Will fit it back on later.
Photo's show it in.
Just need to lengthen the push pull rod about 65-70mm then pull it down and tidy it up.
Also I removed the locking plate, will weld it in place once I have got it all good.
And it misses the Auto's linkages.



Will post photo's of it out of the truck as I need to pack up and get off to work...
Another day tomorrow.

Calvin

[NOBDY]

Not sure how far through you are with the rope guides, but when I set mine up on the race truck, we had spare dome fairleads made to act as fixed rope guides under truck.
Made from alumininm (sp) with 4 indexing holes, so as it wears you rotate it 90 degrees to increase the life. Also have 3mm brackets for these, just weld where required then bolt on guide.
Think centre hole is 20mm, to allow small ropes to be knotted, over all size about 120dia, big radius's on both sides so rope can run at any angle. PM me for pics and price if you are interested. Centre winch's rock!!!!

[kbushnz]

Not sure how far through you are with the rope guides

Haven't got that far yet, was thinking about using stainless instead of aluminium.
Wont corrode under the truck.
Not sure how they would wear..
Just an idea at this stage.
Planning on trying to use only the one to change direction.
With a few loops just to stop it dragging when not under tension.

Calvin

[mudlva]

pvc plumbers pipeing does the same thing if just looking at supporting the rope

[kbushnz]

O.K got the lever mounted properly and links adjusted.

When I mounted it all up yesterday I needed the full sweep of the gates, so I have welded up the center one and made two at each end of the sweep. To latch it in Drive and No drive.

Here is a photo of the modified shifter bracket (it was from a manual trans truck)
The gate part was removed and repositioned (ground off old welds)
And also the rod, which was lengthened 65 mm.


Doing a final fit today and then all the bits are off to be plated.

Calvin

[Madaz]

Are you mounting the pto lever to the body?
If you are, this is a bad idea, as the body will move enough to stop the pto engaging fully, and this problem will only be worse if you have a body lift. At Norwest we struggled with a pto that wouldnt engage fully because of this very reason, once we worked the winch over half speed the pto would kick out.
Not fun at all.
If you mount it to the body you will need to use a cable so that it is unaffected by any body to chassis to gearbox movement.

Cheers

[kbushnz]

Yes I have body mounted it.
I hear what you are saying....and it is a concern.
I have allowed a bit of slop for when its all torqued up.
It will twist side to side and not front to back.
So I can't forsee any issues. My auto's linkages are much tighter and dont pop out of gear when fully torqued up.

Time will tell....

Calvin

[darinz]

FYI I bent the internal selector in my auto due to a solid conection to the selector rather than using a cable. Sure it did happen when I wrote the chassis off (Norwest 2008) but with a cable it wouldn't have been a problem.

[kbushnz]

Got my bits back from plating, they have been electrolysis nickel plated.

In cab lever all done and installed.


And linkages all installed and adjusted with a little bit of free play at each end.



Next step is to complete the winch rebuild and work out where and how to mount it under the truck.
In the process of buying a used CV axle from a FWD car to drive it.

[Big]

Very clever.. hats off..

[mudlva]

the older zuk drive shafts had the same bolt pattern for the pto worth looking into as an old shaft will give you two ujs and a slip join then its just the lenght to be sorted thats the easy part

[kbushnz]

Well got my winch spool back from my plating man. Took a bit to clean it as oil was soaked into the casting.(porous cast steel)



Picked up those welders from Mudlva aka Rohan.
And had a look at his setup....Hmmm nice garage and car lift....
Real man cave !
Anyhow, had a good look at his winch cable routing. And has given me some good idea's.
Thanks Rohan.
Looking forward to see how your / his hydraulic pump gearing up setup runs...
Next stop is Monstr's Nissan...

Calvin

[coxsy]

plating man not a in house job at all was it

[kbushnz]

plating man not a in house job at all was it

Of course ! He needs the practice

Calvin