Prado (KZJ78) PTO mid mount winch

[Heath]

You're a bit of a clever bugger arent ya mate.

Good work, love the fab.

[kbushnz]

You're a bit of a clever bugger arent ya mate

Thanks but just really putting all the good things I have seen in the one project.

Been playing with the free spool today.
Release has been finalised.


And now have tacked in the spring system to hold it in.
Think spring may be overkill but time will tell.


I need to mock up the hydraulic system to see if will push it they way it should.

Where's the best place to get copper brake line and some fittings?

Calvin

[Big]

As Heath says "your a clever barsteward" like how it's coming together and I'm probably going to utilise your idea but use air as I have 2 rams.. Great scott..

[kbushnz]

Hhehehe fill yah boots, most of the winch challenge guys run air rams... But I don't have onboard air like they do for air lockers etc etc..So its back to basics.

Calvin

[Big]

Hhehehe fill yah boots, most of the winch challenge guys run air rams... But I don't have onboard air like they do for air lockers etc etc..So its back to basics.

Calvin

yip I will have onboard air but not them farkers either.. I have already got my a/c pump and a small tank I built which can handle 160 psi and i think my pump can just keep going.. lol like over 300 psi but don't need that much.. and yes it'll work my lockers when I get them
But yes I appreciate basics.. doesn't normally cost lots.. still.... I like what ya doing..

[mudmike]

Sorry for the thread jack calvin. This is for big. if you use air rams a single two way ram is best, also I have bent my free spool arm when it was full of mud and only running 100psi so be careful at higher psi.
good luck, Mike

[Big]

Sorry for the thread jack calvin. This is for big. if you use air rams a single two way ram is best, also I have bent my free spool arm when it was full of mud and only running 100psi so be careful at higher psi.
good luck, Mike

Cheers Mike, I'm all over it so to speak.. I'll be running 160 at the tank, around 95-98 for lockers, and most likely same for free spool maybe a little less just have to see how it all pans out..
Sorry for thread jack again...

[kbushnz]

Sorry for the thread jack calvin. Mike

Hey its on topic so all good to me, plus its good to hear what issues others have had. Put in the old memory banks
Calvin

[kbushnz]

Bit more of an update, have done the final weld in for the pulley and winch brackets.
Worked out the hydro freespool and just need to make a handbrake or original clutch pedal to activate it.

Also here are a few pics of the bolt replacement for winch worm gear housing.
Basically you replace three of the short bolt locations with longer ones. 150mm at a pinch. Picture says it all.
You have to drill out the threads and also remove a small web...



Next is to make up the pto drive.

Calvin

[kbushnz]

Spent Sunday in Woodhill on Patrol.
Gave me a chance to see if anything would hit the winch.
Bottomed out the rear on some drop offs.
Articulated it hard over on that side.
Nothing hit....So can now concentrate on the drive line...And free spool.
And even after wallowing in some muddy bits, stayed relatively clean.
Thanks Jeremy for having a measure of yours.

Calvin

[kbushnz]

Update whatever # it is.
Been out in the garage this week before work and finally made up and trial fitted the freespool release. Looks just like one of those hydraulic hand brakes.

Its fits inside the factory arm rest box between the front seats.
The factory rear heater was leaking, so out it went.
In goes the freespool unit.


Collected some Chrome Molly tube for the pto shaft..And a CV axle assy. Nice and small one. Will work great as long as I dont break it.
Plan to make a spare (thanks Monstr for the advice)
Since its all custom made.

Off up the road soon to buy a flaring tool from Super Cheap....
Its getting close to being finished......

Calvin

[philipw]

Like the Hand brake Calvin, im thinking of doing the same thing to the 105

Phil

[kbushnz]

Ok had a play outside before the rain came.
Plumbed in the actuator for the freespool and here a vid of it working.


Calvin

[mudlva]

looking good

is there anyway of fitting a cable or similar to get you know that the arm is engagaed fully

just thinking that when one is mudbound and all is going horibly wrong it would be good to visualise that the arm is fully engaged as with a pile of mud up there you are then relying entilely on spring preasure

just a thought. of course i dont know how heavy that spring is

[kbushnz]

Yeah I did think of that......
Spring is pretty strong....
Will test it out before giving it the full on bash.
But it should be much the same as the air rams...
At least if the hydraulics fail its held on....
Was thinking about a thin rubber boot to protect it.....
See what happens.
From what I can see the Nissan freespools would be better as they are protected from debris....

Drive shafts to go now.

Calvin

[kbushnz]

Been out playing again in the garage.
My machinist workmate has been busy doing my drive shaft this last week.
Welded it all up today and trial fitted.
I have also moved the factory shear bolt location from "A" to "B".
As the winch is under the truck getting to it in the factory position is near on impossible especially if up the the door sills in mud.
SOOOOO it will be replaced with either a 1/4 inch or 5/16 grade 5 bolts or higher so it wont shear.
Original hole all ratty and flogged out.
Having it at point "B" will allow me to access it thru the trucks floor, when I make a little hatch in it.


Here are some shots of it under the truck.





Also have done the final install of the new "handbrake" operated freespool.



Next job is to drill out the shear pin locations and buy some bolts.
Also have the doughnut hawse made. Oh and buy 45m plus of Dyneema.

Calvin

[niblik]

very coolio's chap... do ya know what the cv's ratin is like for torque etc?

[kbushnz]

very coolio's chap... do ya know what the cv's ratin is like for torque etc?

They are out of an AWD 2L Honda CRV so should be able to take the load....
But time will tell.
Making two sets....
One for spare.

Calvin

[Heath]

CV boots going to be fitted I assume to keep things clean...

[kbushnz]

CV boots going to be fitted I assume to keep things clean...

Yup..... Just a test run before drilling off shear pins and then final assy, some new grease.

Calvin

[kbushnz]

Alllll righty
Got my pto shaft back and assembled.
Fitted and had a play with it driving winch.
Phew it turns the correct way
Now to track down some 4mm bolts and replace the temporary shear pin and spool on some rope.
Here is a little vid of it going. Sorry for the noise but the exhaust was right over my head cough cough


Spooled on my Plasma rope from the electric winch, its about 15m shorter than need but great to test it out.
To get tension on the rope to spool on properly hooked the truck up via a double line pull and dragged the daily runabout down the drive on its handbrake.
And it did spool on nice and neat.
Now to find a weekend to go out and test it.

[mudlva]

very cool fella

but heres something to ponder

a "cruiser auto" as in 60's and 70's have a brake in the auto so in neutral it stops the trans from turning this allows the opperator to then engage reverse to winch out. with your auto it looks like this is not the case (being prados are based on hyluxs) so when you want reverse to winch the rope out you are going to get "grunching" sounds

this is the same case with chevy tranmissions which is why i went to a hydralic winch

the tranmission uses the theory that as the wheels are conected to the rear of the trans this will stop any residual rotation from drive into the neutral gear

i initually comtemplated installing a small disc and capiler opperating of a air switch so that as the shifter moved to neutral it automaticly put preasure onto the pto shaft which in turn will be enough preasur to stop the trans from free turning

this got a bit hard so i went to hydralics ( dont quite know why with a bit of hind sight )

anyway just throwing this out to you to think about

looking good all the same

[kbushnz]

very cool fella

so when you want reverse to winch the rope out you are going to get "grunching" sounds

the tranmission uses the theory that as the wheels are conected to the rear of the trans this will stop any residual rotation from drive into the neutral gear

Thanks Rohan I noticed that today.
I am going to have to have some "Stratigies" to reduce this effect.

Not an issue if driving and winching. Only when winching only.
Also need to put in a 2nd gear start button.
Winching in 1st is sooooooooooo slow and the poor old girl is reving.

[kbushnz]

Had a play with the pto setup today.
Spooled out some rope and tried moving from fwd to rev, pausing in N.
Transfercase in N.

Got no clicking / graunching in the auto.
I think as long as there is a pause in N and let the system settle for a few seconds it should be fine.
If I am winching and under load and I need to back off the winch a bit, it will stop the auto from turning so no freewheeling inside the auto.

Different story when winching and driving as the drive train stops the auto free wheeling inside.

Will give it a test run next time I am on a Woodhill Patrol.
My next few weekends are booked out

[Lynx]

Looks the biz dude, nice work.

Cheers Daniel

[ski]

Hi just a few questions,I am planning on moving my PTO as you have done on my 73 series cruiser,which has been awesome following your thread. When you turn the pto gear around ,is this a big job or a case of pressing out the bearings?. Can I have a measurement from pto gear box to the winch drum ?.When you have finished free spooling and you want to lock the dog clutch ,do you have to turn drum by hand to get the slot to line up? as I have seen a few air ram clutch's not engaging. Have you came acrosss any small ideas that you might share with me now , you have nearly finished. Thanks for shearing your project with every one. Cheers DUDE

[kbushnz]

Hi just a few questions,I am planning on moving my PTO as you have done on my 73 series cruiser,which has been awesome following your thread. When you turn the pto gear around ,is this a big job or a case of pressing out the bearings?
Nope, original gear is located on shaft with a spacer, when you end for end the shaft the gear ends up in the wrong spot. To get it to align again I had 1/4 inch shaved off spacer and a another small spacer of 1/4 inch made. I think it was 1/4 inch. This re positioned the gear back in its original position.Bit fiddly to explain but when you look at it you will understand
Can I have a measurement from pto gear box to the winch drum ? From the alloy casting (rear face)to the drum is approx 900mm but remember my drum is angled.
.When you have finished free spooling and you want to lock the dog clutch ,do you have to turn drum by hand to get the slot to line up? No just either pull the rope or drive the winch a bit. As its spring loaded it pops back in
as I have seen a few air ram clutch's not engaging. Have you came acrosss any small ideas that you might share with me now , you have nearly finished. Ahh thats a secret !
Thanks for shearing your project with every one. Cheers DUDE

[kbushnz]

Well almost the last bit to do.
My machinist has done the last bit for me....Well I think.
He has spun up a fairlead for the rope.
Stainless sort of (17-4ph) , we have a bit laying around.
Will fit in the next weekend or two.
Truck is still dirty from a Woodhill patrol day.

[mercutio]

so pretty shiny

[kbushnz]

Well last job I think has been done on the winch install.
New donut hawse fitted.



Just need some longer rope.....drum is only half full ish with 35m worth.
Should be able to get on 50m

Calvin