1KZ surf transformed to Coil SAS club truck

[hosehustler]

Been on quite a few offroad trips now and love the auto, as those who've followed the thread have known I always intended to do some form of manual control over the auto box, so here's what iv'e almost decided on doing 2 mods

I want to be able to select 2nd from stand still and lock up the torque converter, 1st is already selectable, the other gears aren't that necessary for manual control, although manual operation is possiable for all gears, check this thread for info;
http://www.offroadexpress.co.nz/Forums/ ... 18&t=15615

Done huge reading and here's what I think is the best option.

Do this simple mod to obtain control of 2nd gear;
http://www.fourwheeler.com/techarticles ... index.html

Gear----Solenoids (A343F)

1st - #1 On #2 Off

2nd - #1 On #2 On

3rd - #1 Off #2 On

4th - #1 Off #2 Off

Basically mount a switch and give it 12V feed (missile type)...... with the switch on (12v going directly to no2 solenoid instead of from TCU) and 2 selected it will start off in 2nd and stay there, select D with switch on, it will start in 2nd (instead of 1st) and only change as high as 3rd, turn the switch off and it's back to a standard transmission .



and combine with this TC lock up switch mod;
http://www.lunghd.com/Tech_Articles/Tra ... roller.htm

This will give me manual control of the torque converter lock up in all gears, except 1st

Going to the coast again for Queen's birthday so on a mission to get it sorted

[haydgq]

Been on quite a few offroad trips now and love the auto, as those who've followed the thread have known I always intended to do some form of manual control over the auto box, so here's what iv'e almost decided on doing 2 mods

I want to be able to select 2nd from stand still and lock up the torque converter, 1st is already selectable, the other gears aren't that necessary for manual control, although manual operation is possiable for all gears, check this thread for info;
http://www.offroadexpress.co.nz/Forums/ ... 18&t=15615

Done huge reading and here's what I think is the best option.

Do this simple mod to obtain control of 2nd gear;
http://www.fourwheeler.com/techarticles ... index.html

Gear----Solenoids (A343F)

1st - #1 On #2 Off

2nd - #1 On #2 On

3rd - #1 Off #2 On

4th - #1 Off #2 Off

Basically mount a switch and give it 12V feed (missile type)...... with the switch on (12v going directly to no2 solenoid instead of from TCU) and 2 selected it will start off in 2nd and stay there, select D with switch on, it will start in 2nd (instead of 1st) and only change as high as 3rd, turn the switch off and it's back to a standard transmission .



and combine with this TC lock up switch mod;
http://www.lunghd.com/Tech_Articles/Tra ... roller.htm

This will give me manual control of the torque converter lock up in all gears, except 1st

Going to the coast again for Queen's birthday so on a mission to get it sorted

Yea that was one of my favourite things about my 96 Prado with the 1KZ and auto box was that little button saying 2nd gear start, Wish my 1UZ and factory auto had the same button so ill might have to get the auto sparky when he's wiring my truck to have a play, I would be happy just to have a 2nd gear take off button.

[hosehustler]

It's been on the road now for 10,000k's and almost a year, before I post too much more I just want to say I LOVE IT, it was a great decision to change from the gen 1 beast to the gen 2 not such a beast the upsides of the build were first and foremost COIL comfort, 4 doors and good 2nd family wagon.
I had a tally up of project cost and i achieved;
vehicle(IKZ Surf with new head), prado SAS with 70series cruiser powersteer, all new springs and shocks, brand new included, front and rear lockers, Ramsey winch, 4.88 R&P's, Rims, BFG 33muds, rear disc conversion, front/rear/side barwork, interior fitout, cert REG and WOF all for well under 13G which is reasonable these days......I guess a Safari would be a lot simplier to do but alas it's still.......
anyway I had some ups and downs......downer was ripping the front suspension to bits in the chasm, but at least all my welds held on uppers were I did so many trips this year I lost count, including several grade 5 trips, I didn't get many pics as I prefer to just drive and have fun, but here's a few









Got a heap of trips planned for the next 12months and i'm sure it will have more than a few more battle scars next year

[UBZ]

This truck could teach Mr Toyota a thing or two, about how these trucks should have been made in the first place.
And only running 33's.

Was it a rock that caused the arm to bend like that?
Anything you would change in the way you set the suspension up know that you have had it out on the track?

[hosehustler]

This truck could teach Mr Toyota a thing or two, about how these trucks should have been made in the first place.
And only running 33's.

Was it a rock that caused the arm to bend like that?
Anything you would change in the way you set the suspension up know that you have had it out on the track?

I was winching at the time uphill and against a bank, popped the bead on the left front and rim was well and truly wedged under a large tree root but the chap keeping an eye on the winch couldn't see that at the time due to mud/bank/trees, the call was "keep winching" which I did and the end result was we winched the body off the suspension
Although those arms are inherently weak, gonna look at strengthening them
No wouldn't of done anything different, happy with what it does for what it is

[niblik]

cudo's tim!!

very cool.. its great to see ya still in the game and the rig being put through its paces..

[Steve_t647]

Have you found any weakness that you plan on working out in the truck? Glad you are enjoying it and getting great reliability out of it

[hosehustler]

Have you found any weakness that you plan on working out in the truck? Glad you are enjoying it and getting great reliability out of it

Hi steve, good to catch up with you again on friday night, no the truck is great as is, very reliable and performs as expected, this year we have plenty of trips planned so will get out and enjoy once more

[Hiluxaholic]

Did you have the 80 series springs in rear before setting up ride height of front axle or were the factory rear springs still in there?
Got myself a prado front end to go into my ln131 surf hopfully it works out as well as it did for you.

[hosehustler]

Did you have the 80 series springs in rear before setting up ride height of front axle or were the factory rear springs still in there?
Got myself a prado front end to go into my ln131 surf hopfully it works out as well as it did for you.

Set up my front axle with the 80 series springs in the rear that way you know ride height to weld in the front spring mounts etc.
Good luck with the SAS, it's fun doing the job even though it's a bit of a head scratch at times the results are worth it.

[Hiluxaholic]

Cheers mite end up picking your brains during the build.

[Steve_t647]

Look at the way Tim mounted the front arm's I have seen another in CHCH and driven it and the arm's are mounted close under the chassis.

That bugger is really stiff and doesn't want to flex unless you stand on the brakes and it will lurch up, interesting the first time you experience it.

[hosehustler]

Look at the way Tim mounted the front arm's I have seen another in CHCH and driven it and the arm's are mounted close under the chassis.

That bugger is really stiff and doesn't want to flex unless you stand on the brakes and it will lurch up, interesting the first time you experience it.

So are you saying I got it right or wrong Steve

[Steve_t647]

You got it right mate the more parallel the arm is to the chassis the better, the other one is higher at the back (chassis end) and the mounts remade to have the right caster, when braking the body and engine lurches up and forward and to one side before settling back.

I have never driven yours but the arm pretty much parallel to the chassis is how they were factory and done that way probibly because of this reason.

How have those front bushes been holding up offroad? I know the nissan's chew theirs out and lifted prado's being lighter less so but still do. Just curious if your changing the mounts help yours?

[Hiluxaholic]

Hi There

the prado front axle i sourced already has front manual hubs fitted, is there any advantage fitting a ifs hub with 70 series or hilux stub axles? or will purchasing wheel spacers from 4wd accessories to get correct width work?

[Engineer]

Hi There

the prado front axle i sourced already has front manual hubs fitted, is there any advantage fitting a ifs hub with 70 series or hilux stub axles? or will purchasing wheel spacers from 4wd accessories to get correct width work?

yes itll give the same track as ifs surf. spacing the rotor back 17mm youll be able to mount the caliper on factory mounts.
use the free wheeling hubs that r on there

Ryan.

[Hiluxaholic]

Hi There

the prado front axle i sourced already has front manual hubs fitted, is there any advantage fitting a ifs hub with 70 series or hilux stub axles? or will purchasing wheel spacers from 4wd accessories to get correct width work?

yes itll give the same track as ifs surf. spacing the rotor back 17mm youll be able to mount the caliper on factory mounts.
use the free wheeling hubs that r on there

Ryan.

sorry was that a yes to ifs hub swap or a yes for wheel spacers, From what I have been told they both achieve the same width as a ifs surf setup, just interested in which setup works best

[Engineer]

sorry yes to stub axles etc. try and avoid spacers where you can.

[Hiluxaholic]

sorry yes to stub axles etc. try and avoid spacers where you can.

thanks much appreciated

[hosehustler]

I used the prado swivel housings, prado discs/callipers, hilux stub axles, Wide IFS hubs, SNR4x4 rotor spacers/adaptors, Aisin manual FWHubs.
The result, a front end that's 70mm wider ( which matches the ifs rear axle width), certifiable, strong, and has readily available parts



Widening the axle out and fitting a set of landcruiser offset rims gave the vehicle a good wide stance.


Here's a link to some pics I took when we did the same hub swap on my father's double cab hilux, pics show clearly what the adaptors are for.

http://www.offroadexpress.co.nz/gallery/ifs-hub-swap

[Fakey]

sorry yes to stub axles etc. try and avoid spacers where you can.

Just curious, Why would you avoid spacers?

[Hiluxaholic]

Thanks, Cheers
Where did you get the aisin free wheeling hubs from and the spacers? also were the aisin's suited for the ifs or prado?

[hosehustler]

I got the Aisin hubs off trademe, paid $130 from memory, they came out on solid axle hilux, and cruisers, they were also on some IFS surfs etc but they look the same but have less splines so can't be used.
The spacer i got from Jafa @ http://www.snr4x4.co.nz/wheels-spacers- ... a09a746b5e

I'm thinking you're not quite uderstanding the spacer issue, the adaptors from SNR are not wheel spacers that engineer is talking about wheel spacers bolt to the hub (where the wheel studs are) and then you bolt your wheel rim to the spacer, fine for offroad only vehicles but can't be certified forroad use (think 18mm ones may be max) Jafa sells them as well as you can see on his site.
The SNR adaptor allows the wider ifs hubs to be used and pushes the rotor back to line up with the existing calliper mount and allows the std solid axle disc rotors to be used, so long story short its not a wheel spacer its a rotor spacer so it can be certified!

[Hiluxaholic]

I got the Aisin hubs off trademe, paid $130 from memory, they came out on solid axle hilux, and cruisers, they were also on some IFS surfs etc but they look the same but have less splines so can't be used.
The spacer i got from Jafa @ http://www.snr4x4.co.nz/wheels-spacers- ... a09a746b5e

I'm thinking you're not quite uderstanding the spacer issue, the adaptors from SNR are not wheel spacers that engineer is talking about wheel spacers bolt to the hub (where the wheel studs are) and then you bolt your wheel rim to the spacer, fine for offroad only vehicles but can't be certified forroad use (think 18mm ones may be max) Jafa sells them as well as you can see on his site.
The SNR adaptor allows the wider ifs hubs to be used and pushes the rotor back to line up with the existing calliper mount and allows the std solid axle disc rotors to be used, so long story short its not a wheel spacer its a rotor spacer so it can be certified!

Thanks for the info, I did understand the difference between the spacers. 4wd accessories told me to use the wheel spacers and not to worry about the ifs hubs. strange if they cant be certified. have to keep a eye out for the aisin free wheeling hubs
thanks again

[hosehustler]

Perhaps the rules have changed, give the certifier a call and ask just to be sure.

[Hiluxaholic]

Perhaps the rules have changed, give the certifier a call and ask just to be sure.

Thanks. decided to do it once and do it right so going with ifs hubs. have you herd anything bad about superwinch free wheeling hubs? as they seem to be easyer to obtain than aisin's. Well on trademe anyhow.
Thanks

[rokhound]

Asian are the strongest hub available with out modification. Warn seem to be worst, and superwinch are somewhere in the middle.
Comes down to your loadings and what size tyres you are going to run.

[smurf182]

Asian are the strongest hub available with out modification. Warn seem to be worst, and superwinch are somewhere in the middle.
Comes down to your loadings and what size tyres you are going to run.

Stay well away from ORA brand hubs, they are pretty poorly made. I broke one, replaced with Aisin both sides, been all good since.

[Fakey]

Why do you bother with the rotor spacers? Whats wrong with the original IFS rotors that are made to fit the IFS calipers/hubs? Arent they the same size an vented?

[rokhound]

Why do you bother with the rotor spacers? Whats wrong with the original IFS rotors that are made to fit the IFS calipers/hubs? Arent they the same size an vented?

You have to modify and remount the Caliper to do that and you have to redrill the rotor for the wheel studs (thats the way I have done mine). I believe Tim's reasoning was to be able to able to use all factory parts that are readily available.