Project Iron-Pig: My 1996 Land Cruiser Diesel Conversion
 

My Daily Driver is a 1996 Toyota Land Cruiser FZJ80. I really really like this truck, I just hate the miserable fuel economy offered up by the stock 1FZFE engine... 12MPG on average.

So, I'm putting a diesel in it...

Here's a bit of Toyota Trivia info for you... the FJ62, FJ80, and early FZJ80 Land Cruisers had A440F and A442F automatic transmissions in them which are made by Aisin Seiki. Aisin Seiki coincidentally make most if not all of Toyotas transmissions. Well the A440F and A442F transmissions are very similar in design/construction to the AW450-43LE transmission that is found in MANY vehicles, which include Isuzu NPR Medium Duty Trucks, Mitsu Fuso Medium Duty Trucks, UD Medium Duty Trucks, Hino Medium Duty Trucks, as well as many other japanese trucks and busses. Aisin Seike is the Allison of Japan.

The A440F is an old school fully mechanical automatic trans.
The A442F is electronically shifted, but has mechanically modulated line pressure via a TV cable to the throttle body.
The AW450-43LE is fully electronic, has beefed up internals, more clutches, etc. But is essentially an evolutionary step forward from the above transmissions. The difference? It is RWD while the above are 4WD.

So here is where I'm at...

Here is the recipient:

http://i27.photobucket.com/albums/c1...r/IMG_7798.jpg

I bought a wrecked 99 Mitsubishi Fuso FE-SP box truck with 123k miles for $1800 bucks.

http://i27.photobucket.com/albums/c1...r/IMG_7795.jpg

http://i27.photobucket.com/albums/c1...r/IMG_7796.jpg

I then proceeded to tear the entire truck apart, had a lot of fun with the plasma cutter, and made several trips to the recycling center.

http://i27.photobucket.com/albums/c1...r/IMG_7812.jpg

http://i27.photobucket.com/albums/c1...r/IMG_7815.jpg

http://i27.photobucket.com/albums/c1...r/IMG_7817.jpg

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When all was said and done, there was 1240lbs of Aluminum, and several thousand pounds of lite iron scrap. I made $1280 back in recycling all the stuff. (I'm so green, aren't I? haha)

Here is the 4D34-3AT3B

http://i27.photobucket.com/albums/c1...r/IMG_7819.jpg

http://i27.photobucket.com/albums/c1...r/IMG_7820.jpg

It is a 3.9L, 4 cylinder, turbo-diesel that makes 145HP and 285lb-ft of torque. So more torque and less power than the stock engine. Considering the box trucks get 13-15MPG hauling around 10,000lbs of truck with the aerodrnamics of a brick wall, I think it should do a good deal better in my 6,000lb cruiser with less than half the frontal area of the Fuso. We'll see!

Steam cleaned it a bit...

http://i27.photobucket.com/albums/c1...r/IMG_7969.jpg

Here is the AW450-43LE:

http://i27.photobucket.com/albums/c1...r/IMG_7821.jpg

I forgot to take pictures of the A442F I got from a junkyard before I started tearing it apart, so here are a few pics of one I found online. You can see the similarities.

http://i27.photobucket.com/albums/c1...r/IMG_7697.jpg

http://i27.photobucket.com/albums/c1...r/IMG_7707.jpg

http://i27.photobucket.com/albums/c1...r/IMG_7717.jpg


So what you need to do is swap the 2WD extension housing for the 4WD extension housing, as well as the output shafts. To get the output shaft out, you need to tear down the entire trans.

Here is my A442F upon teardown...

http://i27.photobucket.com/albums/c1...-30-44_424.jpg

My improvised tool for pulling the trans apart.

http://i27.photobucket.com/albums/c1...-20-05_248.jpg

Parts Bag'd and tag'd.

http://i27.photobucket.com/albums/c1...-20-15_419.jpg

All the internals stacked up on the torque converter.

http://i27.photobucket.com/albums/c1...-05-07_222.jpg

I steam cleaned my AW450-43LE and mounted it to an engine stand:

http://i27.photobucket.com/albums/c1...-30-57_538.jpg

Tore than one down too...

http://i27.photobucket.com/albums/c1...-45-48_490.jpg

http://i27.photobucket.com/albums/c1...-23-12_411.jpg

http://i27.photobucket.com/albums/c1...-22-19_387.jpg

Here you can see the differences in the output shafts...

http://i27.photobucket.com/albums/c1...-22-31_470.jpg


So now I'm at the point where I need to put the AW450-43LE back together with the A442F output shaft in place. I ordered a AW450-43LE transmission overhaul kit with new clutches/gaskets/etc., which I should have by this coming weekend. Then I'll spend saturday morning putting the trans back together. I can then bolt the Land Cruiser extension housing and transfer case to this trans. Since the trans mount is on the extension housing, my driveshafts will bolt right up, and installing the motor will be as simple as making the two engine mount brackets, plumbing, wiring, etc. Fun fun!!!

Looks interesting. We got that Land Cruiser here with a Diesel, I think you could only have a Diesel with it.

Excellent work!

The Gland Bruiser screams for a diesel.

The Land Cruiser was offered with both turbo and non-turbo diesel engines in pretty much every other market besides the US. To import a diesel clip to convert using an OEM Toyota engine costs, no joke, at least $10,000 just in parts. Then you're stuck using an engine that is problematic for finding replacement parts here in the states.

Since the Fuso was sold here in large quantities, replacement parts are relatively easy to come by. I'm usually a purist, and I'd prefer the OEM conversion, but in this case the Mitsu swap is just too cheap and easy to pass up.

Thanks! Yes it does :)

Nice work & recycling !
Keep it going.

Very cool project, ought to be very rewarding when finished.

Well, got the trans together this weekend... There were some hicups along the way, but nothing insurmountable.

New clutches getting a good soak in AMSoil beforehand.

http://i27.photobucket.com/albums/c1...r/IMG_8046.jpg

Machined the top and side of the case for clearance of the transfer case lever. Didn't actually get around to installing it, but you'll see it soon enough.

http://i27.photobucket.com/albums/c1...r/IMG_8047.jpg

http://i27.photobucket.com/albums/c1...r/IMG_8048.jpg

Cleaned up the case as best I could.

http://i27.photobucket.com/albums/c1...r/IMG_8049.jpg

http://i27.photobucket.com/albums/c1...r/IMG_8050.jpg

This is Parker OLube, recommended by a forum member on Your Online Offroad 4×4 Tech Resource – IH8MUD.com who is doing a similar build. Stuff worked great for assembly!

http://i27.photobucket.com/albums/c1...r/IMG_8053.jpg

Got all the guts back in the trans... I always forget to take pictures, but here is the trans assembled without the 4WD extension housing on it.

http://i27.photobucket.com/albums/c1...r/IMG_8058.jpg

What is that spacer you may say? It is needed to space out the extension housing, since the AW450-43LE has a larger rear planetary gearset than the A442F.

http://i27.photobucket.com/albums/c1...r/IMG_8059.jpg

1st gasket and custom extended dowel pins:

http://i27.photobucket.com/albums/c1...r/IMG_8060.jpg

Spacer:

http://i27.photobucket.com/albums/c1...r/IMG_8061.jpg

Second gasket and extension housing:

http://i27.photobucket.com/albums/c1...r/IMG_8063.jpg

Trans, Spacer, Extension Housing, Transfer Case:

http://i27.photobucket.com/albums/c1...r/IMG_8065.jpg

Completed Trans, one big mamma jamma!!!

http://i27.photobucket.com/albums/c1...r/IMG_8064.jpg

http://i27.photobucket.com/albums/c1...r/IMG_8066.jpg



Next will be bolting the engine and trans back together, taking care of some other details for getting the engine ready for install, then it's time to pull the truck in, tear the drivetrain out, and get this puppy in place!

Whew, a one-foot driveshaft with double-cardans? Or, . . . ? Am enjoying this build being put up on this site. Very nice work and a great donor vehicle choice.

Haha, actually stock driveshafts, since that's the stock transfer case, and it will be mounted in the stock location. That's the beauty of this whole swap, the entire drivetrain stays stock with the exception of the motor.

Thats the best type of swap of all, nuts and bolts.