BamaBleach's FJ40 buildup

[BamaBleach]

1911 previously said:

Great build!

The 3FE is a super great motor; I would love to put one in my 40. You will need to put an oxygen sensor in your exhaust for it. Probably be best off to use the wiring harness from the 62 also.

I'm envious of your Toy Box. Where are you going to put the gas tank now?
I don't want to move my gas tank, so I'll be going with an Orion transfer case instead of a Toy Box.

Keep posting reports and photos please.

I hear the 3FE really shines behind a manual transmission. Guess I'll find out first hand! The 62 had 2 oxygen sensors so, you're right, I'll have to add those in. I've got some friends with some electrical experience offering to help me so, along with them and the FSM, it shouldn't be too difficult of a swap. I'm going to use as much of the 62 harness as I can.

The only other big obstacles is brake booster clearance and adding an external fuel pump. Others who have done the swap suggest using the MSD 2225 so that's what I'll go with. Oh, and I'll also have to bore out the flywheel a bit to account for the larger sized bolts used with the 3FE setup.

I've been wanting a Toybox since I got the Cruiser so I'm real excited about it. My gas tank is under the passenger seat so I don't think I'll have to move it. We'll see.

Probably won't get much done this weekend because of a rock race our local club is hosting.

[puulboy]

Nice looking 40. The transplant should make you much more intimate with your rig. I look forward to watching your progress
thanks
Don

[1911]

BamaBleach previously said:

I've been wanting a Toybox since I got the Cruiser so I'm real excited about it. My gas tank is under the passenger seat so I don't think I'll have to move it.

DOH! I thought you had a later 40 w/ the tank between the frame rails (like mine). No, you won't have to move it - plenty of real estate under there for you.

[Bert]

Updates?

[VT_RainMan]

Yes, please... This is the second time I have read this thread. It's a good read and one of my dreams some day! You have the same year 40 I want.

[BamaBleach]

I do have some updates but I want to get a little bit more done before I add the pics. I'm halfway done with the toybox install and wanted to finish it before I posted an update.

We did come up with a pretty slick modification to my reverse light switch. I posted a detailed write-up of it on ih8mud and marlin's website. The guys at Marlin liked it enough to add it to their "Tech" section so that was pretty cool.

If you're interested it can be found here:
Modified Reverse Light Switch for Toybox users


Thanks for encouragement! It helps motivate me.

[cheddar]

Man thats a wicked looking build so far.

Keep it up

[Bigpappapunk]

Stoked to hear/see updates

[BamaBleach]

Wow, kind of embarrassing that I haven't updated this thread in so long.

So after getting the 3FE out of the 62 and ordering some parts it was time to get down to buisness.

I was able to find a torrent file for the pdf version of the H42 repair manual. I needed this because I needed to replace the stock output shaft with one supplied with the marlin crawler H42-to-toybox adapter kit.


The new Marlin output shaft:

[BamaBleach]

Replacing the output shaft took some time because we didn't have the best pullers to work with. The manual calls for SST's that we didn't have.

For a good write-up on this process look here:
Marlin Crawler ToyBox Install Instructions


Here's a few pics of us doing it:




Hack job on a bolt head that we used for the puller:


Had to wedge the end of a file in so the bolt couldn't "ride out":