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RicardoJM
01-20-2013, 08:16 PM
We've finished Jeff's 4 speed swap. I was going to do an event report, but the cross member stuff will be good tech content. I'm typing this on my iPad and don't have the pictures to post now.

I really wan to than Brad, Jacob, Brian, Bobby, Randy and Steve for their help with the work. Brad did an awesome job with the welding and gabbing. He and Brian also did a bang up job on doing whatever needed being done. Without the extra help I'm not sure Jeff and I could have wrapped it up in three days.

Jeff was going from a column shift 3sp transmission to a floor shift 4 speed transmission and keeping his three speed vacuum actuated transfer case.

The basic operation involves changing the bell housing, changing the transmission, changing drive shafts changing pinion flanges, and making the torque tube removable.

At a more detailed level; the transmission hump needs to have a hole put in it (for the shift cane), the high/low actuator rod needs to be extended, the reverse light wiring need to be moved, and the column shift components (most but not all) need to be removed.

Day one

Jeff and I started by removing seats and transmission hump. With these out of the way we lifted the truck up and proceeded with removing the starter (disconnect the battery), drive shafts, slave cylinder, and tranny/t-case linkages. We then used the transmission jack to remove the 3 sp transmission and transfer case.

http://www.risingsun4x4club.org/uploads/ricardojm/bcity4sp/bcity4sp_001.jpg

http://www.risingsun4x4club.org/uploads/ricardojm/bcity4sp/bcity4sp_002.jpg

http://www.risingsun4x4club.org/uploads/ricardojm/bcity4sp/bcity4sp_003.jpg

http://www.risingsun4x4club.org/uploads/ricardojm/bcity4sp/bcity4sp_004.jpg

http://www.risingsun4x4club.org/uploads/ricardojm/bcity4sp/bcity4sp_008.jpg

With the big stuff out of the way, we removed the clutch fork, clutch pressure plate, clutch disc and flywheel. All these parts were in good shape and were reinstalled.

http://www.risingsun4x4club.org/uploads/ricardojm/bcity4sp/bcity4sp_010.jpg

http://www.risingsun4x4club.org/uploads/ricardojm/bcity4sp/bcity4sp_009.jpg

Next we removed the exhaust. While removing the nuts at the collector, one of the studs snapped. We disconnected the rear shackle so that we could slide the exhaust assembly backwards. In retrospect, we probably did not have to disconnect the shackle but it seemed like the right thing to do at the time.

http://www.risingsun4x4club.org/uploads/ricardojm/bcity4sp/bcity4sp_011.jpg

Next brought the truck down to the ground so that we could connect the engine hoist to the rear hook on the engine and place a jack under the oil pan. These would support the engine while we removed the 3 sp bell housing and installed the 4 sp bell housing.

http://www.risingsun4x4club.org/uploads/ricardojm/bcity4sp/bcity4sp_013.jpg

http://www.risingsun4x4club.org/uploads/ricardojm/bcity4sp/bcity4sp_014.jpg


Next we removed the bell housing bolts (2 on top and 4 inside) and engine mount bolts (3 on each mount) and removed the 3 sp bell housing.

http://www.risingsun4x4club.org/uploads/ricardojm/bcity4sp/bcity4sp_012.jpg

http://www.risingsun4x4club.org/uploads/ricardojm/bcity4sp/bcity4sp_015.jpg

http://www.risingsun4x4club.org/uploads/ricardojm/bcity4sp/bcity4sp_016.jpg

Next we installed the 4 sp bell housing. Removing the passenger side engine mount made it easier to position the bell housing and get the bolts started. We then reinstalled the engine mount. There engine hoist and jack did an excellent job of keeping the engine in place and Jeff's slender build made the swap seem quite easy as he did all the work inside the space usually occupied by the transmission hump.

http://www.risingsun4x4club.org/uploads/ricardojm/bcity4sp/bcity4sp_018.jpg

http://www.risingsun4x4club.org/uploads/ricardojm/bcity4sp/bcity4sp_021.jpg

This seemed like a good stopping point for the day, so I drove Jeff home and we set Saturday's start time for 9:00 am.



Day two
Brad picked Jeff up and we continued with the days work. Things are a bit hazy as we had a bunch of stuff going on. Brad got to work on making the torque tube removable. First step was to cut the tube flush with the frame, the sawzall made quick work of this. Here the frame is being cleaned up after the tube was cut out.

http://www.risingsun4x4club.org/uploads/ricardojm/bcity4sp/bcity4sp_026.jpg

http://www.risingsun4x4club.org/uploads/ricardojm/bcity4sp/bcity4sp_031.jpg


Next Brad fabricated the plates from a strip of 1/4" X 4" steel, drilled holes and welded nuts to a couple of the plates. Next holes were drilled on the frame so that the plates with the welded nuts could be welded on the frame. The plates were then welded in place on the frame.

Drivers side:

http://www.risingsun4x4club.org/uploads/ricardojm/bcity4sp/bcity4sp_035.jpg

Passenger side:

http://www.risingsun4x4club.org/uploads/ricardojm/bcity4sp/bcity4sp_036.jpg


While Brad was busy on the fabrication, Jeff was re-sealing his 4 sp transmission and getting it ready to mate up to the 3 sp case. Mr. Brady and Randy were replacing the blue air line for Steve's FJ40.

http://www.risingsun4x4club.org/uploads/ricardojm/bcity4sp/bcity4sp_027.jpg

http://www.risingsun4x4club.org/uploads/ricardojm/bcity4sp/bcity4sp_028.jpg

http://www.risingsun4x4club.org/uploads/ricardojm/bcity4sp/bcity4sp_029.jpg

Justin at Redline was able to hook us up with an exhaust manifold and Jeff had purchased a lift from Redline and Randy had an axle that needed to get out to Justin and Justin had a ring and pinion for Randy - so I took a ride out to Calhan while work progressed.

Near the end of day 2, Brad realized we were without the spacer that goes between the transmission and t-case. Without that spacer the gears do not line up inside the t-case. Brad indicate he had an extra spacer at home and despite that we discussed the merits of just pushing forward without and even called out to Ige and Jeff Z. to discuss our situation. We determined the best course of action was to call it a day and do some research.


Day three
Brad brought his extra spacer and it was exactly what was needed.

http://www.risingsun4x4club.org/uploads/ricardojm/bcity4sp/bcity4sp_039.jpg

The transmission was mated up to the t-case (or is that the other way around) and stabbed it into its new home.

http://www.risingsun4x4club.org/uploads/ricardojm/bcity4sp/bcity4sp_045.jpg

http://www.risingsun4x4club.org/uploads/ricardojm/bcity4sp/bcity4sp_048.jpg

http://www.risingsun4x4club.org/uploads/ricardojm/bcity4sp/bcity4sp_049.jpg

Clearance of the vacuum components and floor boards were a bit of an issue, so we rotated the t-case down as we stabbed and then brought it back up. The adjustments on the transmission jack are very handy for this type of precise movement. It was a bit challenging to line up with the pilot bearing, but using some bolts and guides and making small adjustments we arrived at the point where it slid right in.



After that point we had some pizza for lunch and then it was like an episode of Car Warriors. Brent, Brad, Jeff were a flurry of action as pinion flanges were swapped out, drive shafts installed, the torque tube was welded to it plates,

http://www.risingsun4x4club.org/uploads/ricardojm/bcity4sp/bcity4sp_051.jpg

http://www.risingsun4x4club.org/uploads/ricardojm/bcity4sp/bcity4sp_056.jpg


the transmission hump hole was cut,

http://www.risingsun4x4club.org/uploads/ricardojm/bcity4sp/bcity4sp_057.jpg

the old column shift linkages were removed - and oh yeah Jeff to the rig on a test drive - the exhaust was re-installed, etc. etc...

nattybumppo
01-20-2013, 08:57 PM
Great job, guys! Good to hear he will now be cruising in 4 speed style.

bigcity25
01-20-2013, 10:11 PM
There are some standup members here in this club. We really learned a lot and we'll make sure we make a detailed grocery list for what is needed. There was only one real hang up that we discovered and that was amount/type of spacers needed. After gathering all the parts and reading tech links on here and mud I thought I had all my ducks in a row. This project was over a year and a half in the making. But so far it was well worth it. It is going take me a couple of drives to not reach for the column to shift. And also gotta remember 4th gear waiting for me to shift over to it.
Btw thanks again to Ricardo for putting this together, Jeff Zepp and Iggy, for answering their phones, Brad, Brian, Bobby who showed up to wrench, Randy and Dee for their hospitality and Justin at redline for the last minute exhaust manifold. If I missed anyone sorry, my head is mush right now.

FJBRADY
01-21-2013, 09:26 AM
Glad you got it back on the road.

I thought the seats were comfy.:beer:

Well done.:thumb:

Dirt Claude
01-21-2013, 10:49 AM
I had a good time wrenching with you guys, I think it gave me the motivation I needed to get working on my FJ40 again!

nattybumppo
01-21-2013, 12:21 PM
Bring that bad boy to the meeting next month. We want a show and tell!

BBGS
01-22-2013, 05:41 AM
Richardo and the gang , thanks for having me over for my 40's lesson. I'm hoping someone's going to have a 100 tech project out there. Great meeting you all Sunday. Thank you Randy and Dee for hosting.

Looking forward to some of the club events.

Bobby

Air Randy
01-22-2013, 09:25 AM
Nice to meet you and thanks for the pizza!

MDH33
01-22-2013, 10:53 AM
We've finished Jeff's 4 speed swap. I was going to do an event report, but the cross member stuff will be good tech content. I'm typing this on my iPad and don't have the pictures to post now.

I really wan to than Brad, Jacob, Brian, Bobby, Randy and Steve for their help with the work. Brad did an awesome job with the welding and gabbing. He and Brian also did a bang up job on doing whatever needed being done. Without the extra help I'm not sure Jeff and I could have wrapped it up in three days.

Looking forward to your write up Rocardo. :thumb:

Rzeppa
01-23-2013, 12:22 AM
Big City - you need a sig line...;)

bigcity25
01-23-2013, 04:16 AM
Big City - you need a sig line...;)

Got any ideas?

Air Randy
01-23-2013, 09:29 PM
Got any ideas?

How about something like this except with your information in it? :D

Jeff Zepp
Kittredge CO USA
1971 & 1976 FJ40s, 1978 FJ45, 1987 FJ60
Rising Sun 4WD Club, TLCA #4063

Rzeppa
01-24-2013, 06:21 PM
Got any ideas?

Much better! Thank you Jeff!

:thumb:

bigcity25
01-24-2013, 06:56 PM
No worries, smartphones don't show the sig lines

RicardoJM
01-26-2013, 10:49 AM
Pictures and notes have been updated in the first post of the thread.

Rzeppa
01-27-2013, 11:53 AM
Fantastic write up Ricardo! Looks like you all had a good time. I was reading it and looking at the pictures and I made some Tim Allen grunts and my wife, in the next room asked what I was grunting at. She came in and I pointed to the pictures. She just rolled her eyes. :rolleyes:

bigcity25
01-27-2013, 03:55 PM
Thanks Ricardo, I linked it to Facebook so my family and friends can see the write up.

bigcity25
02-13-2013, 12:25 AM
So after a couple of weeks we determined my tranny had a bad input shaft bearing. So on Sunday my 40 was up in the air and a new, smooth running tranny was installed......in about 10 hours. The ability to remove that cross member saved more time than conceivable. We ran out of time to replace the exhaust. I had to just say uncle and take her to a shop in town to get the headers installed. I dropped my rig off this morning before heading into the firehouse. And hopefully get to drive it home tomorrow without stinking if exhaust anymore. We'll keep you updated.

Air Randy
02-13-2013, 08:37 AM
What did you have to do to fix the clutch? Was it just air in the line or did you need to replace the master?

Dirt Claude
02-13-2013, 09:02 AM
Glad to hear the new tranny is much smoother. When we had it on the lift last time, I recall Ricardo mentioning that a couple of the bolts on the cross memeber felt like they may have been stripped. Did everything look okay when you tore it apart?

RicardoJM
02-13-2013, 09:22 AM
Glad to hear the new tranny is much smoother. When we had it on the lift last time, I recall Ricardo mentioning that a couple of the bolts on the cross memeber felt like they may have been stripped. Did everything look okay when you tore it apart?

They looked ok (were not cross threaded stripped) and went back in but Jeff did have to work at it. IIRC, the tolerances are tight and the key is to work all 8 bolts evenly. I would think that opening up the holes on the plates just slightly would resolve the issue. The other thing to keep in mind is to note which side is driver (or passenger) as we initially had it opposite. Once we swapped sides it slid right in (from the rear) and fit snug. :D

rover67
02-13-2013, 09:23 AM
Nice work you guys! Awesome that Randy has it goin' on down there... we are fortunate to have such a generous fellow in the club.

Not sure how I missed the thread.

bummer you had to go back and replace the input shaft bearing... at least it's sweet now!!

bigcity25
02-13-2013, 10:08 AM
The verdict is still out on the clutch. I am waiting to get a phone call today from the shop. I told them about my slave cylinder, lack of return spring and the modification I did to have a return spring. I am not sure if the spring is too heavy and puts too much of a pressure on the slave cylinder. Or the possibility my slave cylinder is bad.

I think the trick to the cross member is to start all the bolts and then snug it down once all the bolts are threaded.

Gotta thank the guys again for all the help and also Justin at redline. I'll be making a trip down there to give him a bunch of free parts.

subzali
02-13-2013, 10:43 AM
...I think the trick to the cross member is to start all the bolts and then snug it down once all the bolts are threaded...

That's good practice for most multi-fastener assemblies :thumb:

bigcity25
02-13-2013, 11:05 PM
Headers on and it's badass. Quiet and no more chocking. The slave cylinder is a different story. I knew my 2f was out of a fj60 and now pretty sure it's a 1986 2f. I have this screwy clutch fork that doesn't have a return spring. When I ordered a slave cylinder I just ordered one for a fj40 4 speed. So long story short the push rod wasn't long enough (story of my life) . The guys at comprehensive auto overcame this and now everything is working fine. That place is a great shop, and prices weren't too bad.

spectre6000
02-14-2013, 12:00 PM
So you're fully operational and back to trouble free DD status?

bigcity25
02-14-2013, 04:30 PM
Yep, knock on wood.