4age suzuki with hilux gbox and diffs

[Antoni]

Ok well my Terrano project was taking forever to cert and in the meantime I needed a daily driver so I picked up a sj413 for 2.5k.

It was riddled with rust, max speed was about 90k and the noises it made horrified me on a daily basis. All that said it used bugger all gas and went well offroad.

The Terrano finally got its cert after almost a year of headaches, mostly paper war not anything I had done wrong. By this stage I was sick of the thing and the Suzuki was growing on me. In the end I decided to sell the Terrano and make a few minor modifications to my little SJ.

[Antoni]

I decided to use a blacktop 4age and w56, I got hilux diffs from a LN106
the diffs weren't too hard to mount up I found the spring mounts were about 50mm out on each side front and rear and decided they would be the easiest to move.

the engine and gearbox on the other hand was not so easy I had to cut away a lot of the transmission tunnel and the engine had to sit a little further forward than I would have liked due to the rear drive shaft angle but I got it in there.

[Antoni]

Once I get some more data I will upload some more photos

At the moment the engine is in and mounted, 90% wired up, the diffs are in and I had to remake the steering arms to change to crossover from the toyota J-arm, I didn't want to use Hi steer as it completely ruins ackerman angle and I figuered if your'e smashing your tie rod up your'e smashing your diff up so dont really see the point. I am using FJ80 TRE's and even bought a tapered reamer from the US to ream the arms I made out to the toy taper. I went with the double arm arrangement but milled the arms out of 90mm round bar rather than weld two together.

Briefly what I have left to do is:

Driveshafts. Shorten and I need some of the larger front transfer case output flanges.
Clutch- What friction disc???complete details below
Fuel lines and tank. braided lines and fittings on order
Brakes - just the hoses and handbrake cables
Mount the shocks
Finish the steering off, ream arms and make tie rod and draglink
Radiator, mount and plumb up
flare the hell out of the guards for larger wheels.
Speed Sensor- G'box had mechanical drive and I need an electronic sensor Wrecker solved this one
...and a million other little things in sure im missing.

[Antoni]

transmission hole, W56 was a little larger

[Antoni]

steering arms

[Antoni]

I used Leaf spring eye bushes to mount the engine and gbox I dont have a lot of room for movement but hopefully they will reduce noise and vibration a little

[Antoni]

Well today I rang up partsmaster to get a clutch went through a massive ordeal to workout the correct friction plate, then the dude rang exedy and they make a clutch kit for 4age to w55 w56 etc will post part number if it fits and hopefully save others hours of research. I think it is: TYK-7146HD but will confirm when it all does or doesn't work....

[shortylux]

Awesome work mate! Sounds like you are nearly there.

Are you still using the (divorced) Suzuki transfercase? or a hilux transfer? Could you have moved your engine reward like you wanted if you used a t-case off a 4spd toyota gearbox? They have the levers coming straight out the top and are 150 odd mm shorter than a normal toyota t-case and will bolt to a w56 (I believe).

Arron.

[Antoni]

Maybe, I wasn't aware of another transfer case that would fit im using the hilux RF1A transfer case, but yeah I could have moved it back a little but blacktops have the distributor on the rear of the engine so wasn't alot more room to move it rearward anyway without cutting up the firewall.
Well today I picked up the clutch kit Exedy TYK-7146HD the plates are definitely correct just not 100% on the release bearing on the bright side its a sports tuff performance clutch and I got it for trade $325 odd bucks not bad I thought. Heres a photo of the engine and box before I installed it.

I have now recieved my braided hose and fittings for the fuel lines, radiator and rwd 4age backing plate.

The fittings I ordered from summit came with a part missing so will have to wait and see their response to that one..
The radiator (trademe special) was for the most part good, however the drain bung which screws into a random as all hell tapered thread doesn't wind in enough to seat the o-ring its something like 9/16 18 TPI.
Finally the backing plate (also trademe special) was water jet cut aluminium and was actually mostly good despite a few large scratch/ gouge marks, but hey its not a show car.

Also started to look at how to thread cut my draglink and tie rod, M23x 1.5 cheers toyota that will be fun. I will doing it on a lathe so I'll do a few practice runs first to make sure I can achieve a good fit up.

Edit : 04 Aug 13
I now have most the stuff I need to complete the truck, I cut the threads for the Tie rod and draglink over the w.e took forever but beats buying two taps at some insane price they were over $100 ea. I went to ream out the sj pitman arm to fj80 taper then realised there would be about 6mm left of the thing so I cut off the splined section cleaned it up on the lathe and pressed/welded it in to a piece of 20mm flat bar, well before anyone else chimes in yes I know I can't do that legally but it'll have to do for now until I can get one made by some steering guru that the hobby car tech manual is talking about.
Also last weekend I went out to pick a part and got a 1" brake master cylinder and clutch master cylinder.. sooo cheap wish I could buy everything there. Finally I also deisigned my exhaust manifold up and went and got all the pipe for it, I was going to do it in stainless but price and pipe sizings were against me so steel it is. Ignore the crazy flange it was to help visualise space constaints.

[Antoni]

Well I have kind of come to a turning point in the project, I have decided to put in coils and 4 link it might be more than I can chew but we'll see. Also for anyone who has ran into this problem before you can buy hollow bar from fletchers 35mm OD 20mm ID perfect for FJ80 Tie rod ends, well provided you have access to a lathe and know how to cut threads.

I have also decided to dry sump the engine, I picked up 2x Schadek 26mm Air cooled VW engine oil pumps off trademe and Im probably 50% there with making a pump from them.

I have also 50% finished my Hilux Powersteering Box conversion. worked out really well but I ruined both the intermediate shafts making a temp one so now I need a new shaft probably try get a prado one and have it resplined to the suzuki spline on the steering column end (does circle track or anywhere else do this??) Also does anyone with 2 Universals on their 4wd that has been through cert know how you go about supporting the shaft with a sleeve or bearings, strange cert rule far as im concerned... my driveshaft has two uni's and it doesnt need bearings to support it.

[Mattrade]

Hey man been enjoying your build, how's it coming along?