another terrano/safari project = terrari

[passengerpete]

i keep getting sidetracked with easy stuff i really need to make a start on the gearbox conversion so that's this weeks mission.

[passengerpete]

put in new springs its a bit higher then i was expecting

i might have to extend the links one day

[skid4x4]

hi there, youve put in some good work here mate, looking foward to hearing about the safari gearbox conversion and SAS, ive been thinking a bit about a pig box behind my td27t if i continue having troubles with the front diff, i did a sas on my ute but flipped a beam instead to go with std box, but if i continue with diff troubles i will be goin pig or cruiser beam and not flipping it,

how are you planning to get around the sump issue of clearance for the drive shaft? ive got mine sitting pretty high but still woulndt have enough room for a diff head and drive shaft on the right side without cutting and patching the sump in some way,

will be whatching, cheers keep up the good work

[passengerpete]

hi there, youve put in some good work here mate, looking foward to hearing about the safari gearbox conversion and SAS, ive been thinking a bit about a pig box behind my td27t if i continue having troubles with the front diff, i did a sas on my ute but flipped a beam instead to go with std box, but if i continue with diff troubles i will be goin pig or cruiser beam and not flipping it,

how are you planning to get around the sump issue of clearance for the drive shaft? ive got mine sitting pretty high but still woulndt have enough room for a diff head and drive shaft on the right side without cutting and patching the sump in some way,

will be whatching, cheers keep up the good work

thanks mate the gearbox is a pain in the ass but progress is being made, thanks for the heads up for the sump clearance problem as i have not even thought about that yet will tackle that when i get there. ya sound like ya got a cool truck there got any pic or a build up thread would love to see it.

[passengerpete]

ok back form christmas holidays so can play on truck for a few days before i go back to work.
good news a td27t clutch will fit on a td42 input shaft spline

[passengerpete]

was not to sure where to start, but i thought the input shaft is a common factor so mate some ruff template to get a visual to so where things will sit made a engine side and a gearbox side

[passengerpete]

so this is where it will all sit.

[passengerpete]

now i have to make plans with exact measurements for spigot center bush and all the bolt holes this will suck hard and i might have to do it more then once to get it perfect. i can not find any technical drawing or measurement's of the td27t on the web was hoping to find a cad drawing oh well that's life.
originally i was going to make a adapter plate but now im thinking about just making a new bell housing out of plate steel. so should look super ugly with welded plates every where but then get it milled flat.

[passengerpete]

was reading some where here on ore may be sininmud t1/2 posts, about the clutch starting to slip with the boost turned up, so was thinking about upgrading the clutch system, now apparently the 3.2 diesel r50 terrano the qd32 i think it is has a bigger flywheel and bolts to the td27t crank so could use this clutch maybe ? i don't know with out trying tho just a thought.

[passengerpete]

today i put the flywheel and clutch so i could measure where every thing sat on the input shaft. and it looks very close, will get a engineer to double check my measurements. the good news is that the td42 input shaft nose is a exact match for the td27t crank spigot, meaning can just buy off the shelf when maintenance time roll around.so std spigot bearing, std clutch, on std td42 gearbox, with std td42 clutch fork and bearing. and std gq slave cylinder. the only custom part is the bell housing, well so far i wont count my chickens before they catch, but its looking like it might just work out.

[passengerpete]

a hairy mate was curious to see what all the fuss was about.

[passengerpete]

gq gearbox into wd21 is full steam ahead. just got some plate steel its over at the engineers (B spec) getting cut to shape and holes drilled and stud bits to. the two side that is, td27t to FS5R50A once there done its plating around to suit. so now im just waiting. so lifted up car on one side to see what size shocks i need

i could have gone a bit higher but i did not want to risk any happening in this shaky city of mine.so i think i need some shocks that are 650mm open 500mm closed and 560mm sitting flat on ground. im really unsure of what im doing or even if im doing it right ? im guessing that i just try to find some shocks about that length.
now who wants to give me a fantastic deal on some shocks

[slide]

Awesome progress! Keep them pictures coming
Is the td42 bellhousing cast iron?
Maybe could make an adapter plate which would bolt to engine, them bolt gearbox to the plate? And to allow for extra length that it would add, machine the bellhousing down by the thickness of plate.
Without having bellhousing here to inspect its hard to tell, but machine 2mm off gearbox end, 4mm from engine end and remove 3mm thick backing plate = 10mm adapter plate adding only 1mm of length to bellhousing effective length?
Sound good or am I maybe missing something?

[passengerpete]

Awesome progress! Keep them pictures coming
Is the td42 bellhousing cast iron?
Maybe could make an adapter plate which would bolt to engine, them bolt gearbox to the plate? And to allow for extra length that it would add, machine the bellhousing down by the thickness of plate.
Without having bellhousing here to inspect its hard to tell, but machine 2mm off gearbox end, 4mm from engine end and remove 3mm thick backing plate = 10mm adapter plate adding only 1mm of length to bellhousing effective length?
Sound good or am I maybe missing something?

yes bellhousing is cast iron.
and yes your right it can be done that way. and i could still do it that way if need be, im getting both sides done just so i have a back up plan, at the mo im still going with the bellhousing plan simply as there is less machining so less cost hopefully,

[passengerpete]

small up date
have now got all bolt centers and studs exactly right and now on computer. so got some scrap and did a check

[passengerpete]

will get the real plates i need back next week. but i do have a small problem of where the clutch bearing sit against the pressure plate, as in dose it rest against it or a few mm away ?. also how much threw out should i be aiming for ? i need this info so i can work out the distance between the motor and gearsak. i guess its not the end of the world as i could use spacers i i miscalculate.

[klompy]

It needs a small amount of clearance maybe 2mm.You dont want it spinning on the pressure plate when the clutch is disengaged or it will wear out prematurely.

[slide]

And leave plently of room to allow for the clutch to wear. As clutch wears, the pressure-plate fingers move out (away from engine).

[passengerpete]

thanks for that chaps much appreciated.
i have not done much on truck this week. as its my first week back at work and cant be arsed, but i have ordered some shocks of 4wd acc will pick em up Monday night.

[passengerpete]

got shocks, lots fatter then std ones. i google the part no, and there off a safari explains why the bushes are to big. so will get a sleeve made made up or a new bush whatever works out cheep.

[passengerpete]

nothing new on gearbox conversions at mo still waiting on plates to get done. im looking for a gq rear drive shaft if any has one to sell. and a pto for a y60 safari which seam rather hard to find. as all the tm ones are only selling the winch drum part.

[niblik]

a pto for a y60 safari which seam rather hard to find. as all the tm ones are only selling the winch drum part.

not a possibility to fab one up dude?

[wax]

Its an interesting thing your doing and massive under taking good effort
Why do you not just use the terrano II gearbox ??

[kbjj]

Its an interesting thing your doing and massive under taking good effort
Why do you not just use the terrano II gearbox ??

A standard front axel can be used for an SAS, and he can have a PTO winch. I'm jealouse already. I'm watching with interest

[wax]

Ok that makes sense. Good work Carry on

[passengerpete]

a pto for a y60 safari which seam rather hard to find. as all the tm ones are only selling the winch drum part.

not a possibility to fab one up dude?

well to be honest i have not even thought of that. i guess its only a box with some shafts and gears in it. should not be any harder then what what im doing at mo. jokes yea nar that's above my skill level at mo

i read some where that ya can get the bronze gears for the ptos. so they must run on the gear in the gearbox that's in the center of the the pto cover plate ?.
im guessing the pto run all the time but with a dog engagement to use the winch ? how dose the factory safari do it ? i need to have a look at one first before i commit to anything, nothing like diving in the deep end head first.

[meatc]

I know of a PTO that might be avalible. The winch is stuffed (worm wound its way out) Truck was purchased to donate some parts to another project, will talk to the owner tomorrow and see if he wants to part it off the box.

[passengerpete]

I know of a PTO that might be avalible. The winch is stuffed (worm wound its way out) Truck was purchased to donate some parts to another project, will talk to the owner tomorrow and see if he wants to part it off the box.

yea mate i would be real keen if its for sale. will save a heap of time, even if it damaged it will be fine, can rebuild/ make till it works again.

[passengerpete]

bell housing almost finished just getting a slave cylinder holder sorted, its been a absolute pig of a job. i will never do any thing like this again, at lest it will be indestructible. im thinking of getting a mould made, and getting another one made in aluminium to sell depending on cost. tho i guess their wont be much of a market for em. will start riping out old terrano auto box next week and start putting in patrol gearbox, this will require a new fabricated cross member and im not a certified welder so will have to get someone else to do that then a drive shaft.

[tomsoffroad]

im not a certified welder so will have to get someone else to do that

Ohh Ohh Ohh (jumping up and down hand in the air ) I am