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91 FJ80 Build

Got the motor resealed and the transmission. Going back together to hopefully not come out again.
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It may be an optical illusion, but it looks like the shaft for the alternator is wobbling.
 
Will Scarlet said:
It may be an optical illusion, but it looks like the shaft for the alternator is wobbling.
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I didn’t notice earlier but I think you’re right. It’s a brand new alternator from summit. I’ll look at it closer and see what’s happening.
 
Nice, I'm totally into the 6 speed auto over the 4speed. I didn't even realize there was a Gen 4 4.8, I may steal your idea :flipoff2:

You may have mentioned it, but what's your tcase set up as far as high and low range gears?

I'd like to put an lt230 behind a 6l80e as I think it would be perfect ratios.
 
YotaAtieToo said:
Nice, I'm totally into the 6 speed auto over the 4speed. I didn't even realize there was a Gen 4 4.8, I may steal your idea :flipoff2:

You may have mentioned it, but what's your tcase set up as far as high and low range gears?

I'd like to put an lt230 behind a 6l80e as I think it would be perfect ratios.
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I'm using the factory FJ80 transfer case. Low range is 2.49:1 and High range is 1:1.
 
YotaAtieToo said:
Gotcha, with the 4:1 1st it will probably be pretty good for most situations.

The 80 cases are interesting with the 1.1:1 high gears as an option.
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The 80 series case has some options. 1.1:1 high range as well as a 3:1 low. So you can get better overdrive and better crawl gears in one unit.
 
Rugger99 said:
Especially Those of us with 1991 FJ 80's..." types in Toyota part number....NLA " :laughing:
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It feels like every damn part is NLA. 🤣 Get pretty good at Jerry rigging newer parts to fit the older applications
 
YotaAtieToo said:
Any idea what the wieght difference between the stock engine and trans and the new stuff?

Is the 4.8 aluminum or iron block?
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Iron block 4.8l

The front end looks lighter with the 4.8l/6l80 vs the 3FE/A440 combo. I didn't weigh them but I wish I had.

Google fu shows the following: (But I don't know about the A440 weight that transmission is massive compared to the 6L80.)
3FE weighs ~650lbs and the A440 weighs ~215ilbs dry for a total of ~865lbs
4.8l weighs ~580lbs and the 6L80 weighs ~195lbs dry for a total of ~775lbs

So its a little lighter.
 
I need to air up the tires to a more road worthy pressure. I think the Autozone power steering pump is dead, because it intermittently works. I need to plumb the crankcase vent on the passenger valve cover to the intake because currently it’s an unmetered air leak that whistles 🤣. Need to order fittings to get the AC connected. Also need to adjust the throw of the shift lever because it’s nowhere near where it needs to be. But it was a successful first ride and it didn’t explode so that’s good. :smokin:
 
:homer:
Did some more work to it. Was driving it off and on to the store or on errands. All within 5 miles of the house or so and it was working good. I was dragging my feet on the alternator replacement just because I was lazy. Noticed that the voltage was dropping significantly under load during acceleration. Contacted Summit and had them send a replacement alternator. That one arrived in the shipping box in worse shape than the alternator installed on the truck. So I went to Napa and bought a Denso reman. Voila, perfect voltage and guess what? The power steering pump I thought that was crapping out was actually the crummy Summit alternator intermittently seizing :homer::homer::laughing: Bonus from buying a non crappy product.

Drove it around town some more and everything was good.

After Hurricane Helene my church group volunteered to help with some hurricane clean up about 4 hours south. Decided to throw the front end on the truck the day before and drive it down. What could go wrong? 250ish miles and not properly tuned. I figured I drove my ole 22r with a terribly tuned carburetor for years with no ill effects so the legendary 4.8l should have no problems. Well I was right, it ran great and is going to get tuned this Friday so it will run better.

My gas pedal bracket was not so lucky. I was playing around with making it more ergonomically friendly and left one of the 3d printed prototypes in. Turns out 40 minutes is all the PLA could take :lmao::homer: Had to turn around and drive home to grab the non ergonomic ABS bracket then drive back again. Worked for the 4 hours down, the day and a half puttering around and the 4 hours back up. Just need to print an ABS version of the more ergonomic bracket.
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Still haven’t wired in the PNP switch so no reverse lights and no gear indicator lights on the combo meter :homer:
 
A few updates but nothing too crazy. Been driving around town still with it not fully tuned. That whole adventure is frustrating. Took it to a guy local that had a decent reputation. Turns out he isn’t as familiar with Gen 4s as he let on. He would flash the module then it would see a P0606 throttle error. He wasn’t aware of (and I don’t know all the nuances) that you have to match the ECU hard programming with the tune with the throttle pedal. Spent 2 days ****ing around with that and confirmed with Speartech (who deleted VATS and set up that start up tune) that the local guy didn’t know what he was doing :homer:

So decided to send it. Bought a cheap laptop then HPTuner then an AEM wideband and we’ll take a whack at it. What’s the worst that can happen :homer:

Added the o2 bung after the crossover so it reads both banks.
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Installed on the truck:
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Runs a tad rich 😮 :homer:



Hopefully I can spend some time tomorrow doing the MAF calibration and getting the fuel trims back to a reasonable level.
 
Friends invited me to go to the Daniel Boone Backcountry Byway for Labor Day. So I decided I should probably install the RCVs I’ve had in the Garage for around a year. That snowballed into I should just remove the axle housing and paint it so it matches the rear.

But I didn’t decide to do that until I half tore apart the axle and saw how soupie the birfs were.

So I pulled the housing and the diff and wiped out the axle housing and 3rd the best I could then pressure washed the housing painted it and reassembled with the RCVs, new trunion bearings, new wheel bearings and new drive flanges. I really wish I could have put a locker in but it’s not in the budget currently.
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I also replaced the bushings in the track bar with some energy suspension ones. The driver caliper had 2 seized pistons and the replacement Napa caliper had a single seized piston 🤦‍♂️. Caliper from Oreilly to the rescue.

The bushings for the shock have seen some abuse throughout the years and the driver shock was starting to make noise as it was pivoting in the mounts. Ordered some replacement bushings that were too small so I 3d printed a spacer that adds height to the backside of the bushing. No more loose bushings. Hopefully I’ll get new shocks and springs sometime in the near future lol
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Back on all 4. Burnished the brakes and no more noises from the birfields. Also washed the wheels because that’s important :Homer: :flipoff2:
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So I need to get the reverse lights working.
Maybe fix the AC.
Maybe install my PRP seats.
Secure some of the loose wiring.
Probably some other things if I’m motivated lol
 
You’re out in my neck of the woods this weekend. The weather is freaking incredible and it’s killing me to not be able to go play in the woods. Post pics from your trip!
 
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