Hilux 4x4 Forum

Sifu-Lux

Your vehicle looks awesome David !

What shocks are you running in front? You seem to get a lot of wheel drop.

Sifu-Lux

With the underside work done, I turned to the cab. Since all the seats and vinyl mats were out, I decided to replace the vinyl with carpets. I had some offcuts I had from the last carpeting of the house. First I installed a layer of 10mm SVA 45 foam rubber from Sondor which I bought yesterday. This ...

Sifu-Lux

This afternoon I installed the two transfer case mountings, and then re-connected the speedo cable. This just makes it after the re-routing, not a centimeter to spare :o . Dual transfer case mounts fitted.JPG Next was the 4WD switch wiring which I had previously lengthened. 4WD switch wiring install...

Sifu-Lux

This contraption worked really well and allowed me to lift the transfer case with ease on my own and into position (just a hell of a lot of nut turning though :lol: ) Raising the dual transfer case into position for installation.JPG I replaced the oil seal on the transmission output end, greased the...

Sifu-Lux

So last night I decided to install the dual transfer case setup back onto the transmission. All filled with enthusiasm I picked up the transfer cases and carried the setup to the Hilux (bloody heavy, must weight ~35kg now at least). I put it down on the floor and then lay down beside it and tried to...

Sifu-Lux

missouriman wrote:that shifter should set down in the hole.
not just on it like the picture.

It does, I just put it like that for the picture, otherwise you see nothing

Sifu-Lux

Hey Mark, life just isn't fair :wink: At least you've got the experience... Here is the crawl box gear stick lever that I cleaned up yesterday to fit the modified shift rod. Just enough clearance for heat expansion :eh: Cleaned up gear lever selector tip to fit modified shift rod.JPG Tonight was flo...

Sifu-Lux

Thanks for the encouragement and feedback :thumbup: Tonight I got back in the garage and fitted the front and rear output flanges to the transfer case, as well as extending the 4WD switch wire with some silicone high temp wire and finishing it off with heatshrink. My transfer case was painted at som...

Sifu-Lux

I then stripped the rear main shaft to remove the old 2.28:1 main gear and replace it with the new 4.7:1 main output gear. Fitting the new gear to the main output shaft.JPG I then assembled the transfer case and installed the top shift conversion kit, which changes the forward shift transfer box to ...

Sifu-Lux

Got busy again at lunch time today and worked until 7 PM tonight (Andy, you can calculate the efficiency if you want :twisted: ) I stripped the transfer case and 4WD section right down to the indiviual components, sorted everthing into containers and then went and washed all the housings with engine...

Sifu-Lux

This afternoon I started work on stripping the Hilux. First up was to remove the interior seats and vinyl mats so it will be easy to work when I need to cut the floor pan for the extra gear sticks. Interior stripped.JPG With that done, I removed the front and rear prop shafts, then put a jack under ...

Sifu-Lux

No, JUST the shipping !! I did a quick calc now, $1028 parts, ~$800 shipping

Sifu-Lux

Thanks for the input, I was going to use some marking blue to check the clearancing area, I guess spraypaint would work too. I will use two transfer case mounts, my original, and a used donor one from the crawler box original transmission. I bought a Trail Gear replacement dual transfer case cross m...

Sifu-Lux

The man reason it is better to fix it from the inside (tyre off rim) is that you can inspect the inside of the tyre to see if any other damage was done by the object that penetrated it. I've seen a nail penetrate a tyre in the shoulder area of the tread, and the part inside the tyre moved around and...

Sifu-Lux

A real pity, I'll be in the USA then...

Sifu-Lux

Last night I built the crawl box up into the adaptor. I won't go into all the details of assembly here, but Trail Gear's web site had excellent instructions and video clips if you are interested. First I had to weld a piece of key stock onto the existing high low shift rod so the high low gear stick...

Sifu-Lux

Also got a whole selection of gearknobs for the twin stick conversion kit and front crawl box high low selector. This is how they come, made from good quality rubber TG 471 gearknob.JPG But, these look a bit boring and you can't really see the lettering so easily, especially when you have 4 gear sti...

Sifu-Lux

OK, so on with the show. My parts finally arrived end January just before I had to go to Germany, so I spent the whole time wishing I was back :roll: I must say, a very comprehensive kit of parts, nuts, bolts, seals and gaskets etc. Here are some pics of what I got TG Dual adaptor kit.JPG All the nu...

Sifu-Lux

My dual case crawler will not be Marlin, but Trail Gear, and I'll carry on documenting it here: viewtopic.php?f=92&t=9776

The parts arrived last week, and I'll run 2.28:1 in the front crawler box, and 4.7:1 in the rear with twin stick shifters.

Sifu-Lux

Good to see you here from the Capri forum :) I spent some time there getting info for my Ford V6.

Welcome !

Sifu-Lux

Business trip, looking for some equipment for our plant. At least Paris is warmer 3 deg C :)

Sifu-Lux

BenHur wrote:
Sifu-Lux wrote:O Battles scars for the day

Andrew

Do I see a project for a home built integrated bullbar on the horizon?

Hmmm, I almost took the bullbar off a few weeks ago to do some measuring, glad I didn't...

Glad to hear you weren't to badly hurt in your accident, and hope you recover soon.

Sifu-Lux

Andrew as far as I know the grey hilux has a turbo diesel and the white one has a 2.7VVTi engine. Or at least that is what the guy from LA Sport told me. :lol: :lol: If thats the case then I feel even better :thumbup: Power to the Ford V6 :mrgreen: I am sitting in the airport in Hannover, Germany n...

Sifu-Lux

Niel, you can get from these guys:

http://www.rubiconautomation.co.za/inde ... &Itemid=41

They are opening a branch in Cape Town within the next weeks.

Sifu-Lux

On Saturday I joined the EC-Offroad outing to Loerie arranged by Barto. You can see his trail report here: http://www.ec-offroad.co.za/trip-report/loerie-4x4-trail-january-2009 It was a great day out, with a big group, but still a lot of fun. It is also nice to see what the other vehicles are capabl...

Sifu-Lux

I installed a small 2 litre tank in the engine bay when I installed the ARB compressor for the diff locks. That way the system has pressure with a reserve volume, and the compressor doesn't have to run everytime you engage the lockers. I used a Festo stainless steel air receiver and also connected i...

Sifu-Lux

If you have a look at modern engines with variable geometry intake manifolds, you will see that when the engine revs are low, with a lower demand for air (say under 3000 RPM) the variable geometry intake runner is switched to a longer intake length, which increases the velocity of the incoming air c...

Sifu-Lux

As far as I know, Cruiser vented discs (not sure which model) work with IFS model front brake calipers. Just have to check your wheel clearance after the mod/ May need front wheel spacers depending on which rims you have. See here: http://www.hilux4x4.co.za/views/viewtopic.php?f=92&t=2906 Maybe ...

Sifu-Lux

Hi Ewald,

Here's a spreadsheet just for you with the part numbers and approximate costs for the front axle overhaul, excl labour

Everything you need

Hilux SFA front axle overhaul costs and parts.xls: (32.5 KiB) Downloaded 147 times

Sifu-Lux

Cool, thanks for the tips. If I get the parts this month I'll probably start in February when I'm back from Germany. Can't wait :)

Sifu-Lux

Trevor, alles wat jy nodig het is hier viewtopic.php?f=92&t=9011&start=0

Lekker vuil raak :)

Sifu-Lux

Because I'm such a helpful chap, I put the gearbox back so you can see pics in situ with perspective :twisted: Riaan (ToyX4) also wanted the wiring colours, so I did some work tonight :mrgreen: Here is a pic of the wiring running from the 4WD switch (red wire with yellow trace marked R-Y in workshop...

Sifu-Lux

: Toilet roll.jpg (13.03 KiB) Viewed 3977 times

and

: tabard.jpg (5.22 KiB) Viewed 3977 times

Sifu-Lux

Sifu-Lux

Here is a table I found for decoding all the Toyota axle codes:

Sifu-Lux

Bead blasted all the donor parts today. They look like new now

: Transfer crawler case and parts bead blasted clean.JPG (23.62 KiB) Viewed 9572 times

Sifu-Lux

The reverse light switch is on the drivers side of the G52 gearbox. Follow the wires, it's the front one. The rear switch is for the 4WD indicator light.

Sifu-Lux

If you clean the shims, you'll see they have a number on them indicating their thickness. Then just order new ones from the dealer. I think they were R 8.00 each or something when I enquired. I think mine had 3 shims each side. 1mm, 0.2mm and 0.1mm. Both sides were the same. Front steering knuckle s...

Sifu-Lux

Graeme, why do you need to work out the new shims? Are you rebuilding the axle and suspect it is bent/out of alignment, or just want to check. I just re-used the old shims, which were still in good condition. If you really need to do this, contact Ronald (Diesel Dog) on the forum, he has a special m...

Sifu-Lux

OK, so back at work this week :cry: This does have some advantages though :twisted: I prepared the donor parts and taped off the areas I want to keep protected when I get them bead blasted tomorrow. Transfer crawler case and parts ready for bead blasting.JPG I ordered new transfer case output flange...

Sifu-Lux

I do understand all that Andrew, but the two flanges you show above have different internal diameters (possibly a different no of splines as well) ..... my question was therefore, are the out-put shafts the same diameter for the front as for the back, or is the shaft for the smaller i/d flange step...

Sifu-Lux

Andy, I am trying to understand your question, but here's a pic of what I plan to do. Same as Simoan Morris, and pic courtesy of his Marlin Crawler conversion.

: 36975164164be4227b6c42df12d465b78eca7651255e18125fd9f4e7.jpg (100.11 KiB) Viewed 9626 times

Sifu-Lux

After I thought I would need to buy a speedo cable extension due to the transfer case moving backwards, I was advised that it is not necessary, and that the speedo cable can be re-routed to allow extra slack. I re-routed the cable this afternoon, and did gain a bit more length. Whether this will be ...

Sifu-Lux

Ah, I see you have the same idea as me. Maybe you WILL make some dimensional drawings (Please :) )

Maybe ask Johann (Scorpion) who made his viewtopic.php?f=98&t=3426&hilit=Uber+hilux&start=280

Sifu-Lux

Quintin, the biggest tyre size you can run in standard setup in 265/75R15 / 31/10.5R15 without catching anything. I used to even get slight rubbing on full lock and max articulation with this size on the rear of the front wheel wells. I am running OME suspension. To fit 33" tyres you need to mo...

Sifu-Lux

Here is a scan of the owners manual from an '87 import DC Hliux.

Timing for the 4Y is 8 deg BTDC as Bretton said.

Sifu-Lux

Hmmm, I think you have inspired me to chuck out that vinyl flooring in my Lux when I do the dual transfer conversion, as I will have to take the seats out anyway. I am thinking of adding a nice layer of sound deadening under the carpet too, maybe something from Sondor like: http://www.sondor.co.za/p...

Sifu-Lux

Andy, great minds must think alike. I thought of that while having some tea and cake this afternoon. I went and bought a 1/2" drive universal joint for my sockets so I can maneuvre in the tight space.

Sifu-Lux

Now I need some advice from the fundi's who've done this before. I have been told it is possible to remove the rear transfer case section and 4WD section from the Hilux without dropping the entire gearbox. This would be an easier and lighter option, seeing as i'm doing this on my own :shock: The tra...

Sifu-Lux

Have you checked if the vacuum advance on the distributor is working properly? Check for vacuum leaks - the 4Y has more vacuum connections than the Hoover factory :)

Sifu-Lux

Welcome Zane :thumbup: If you need any advice and I'm able to help, PM me. I've done quite a few things to my Lux in the last 5 years :shifty: For outings to trails, I usually go with Barto and Chris from http://www.ec-offroad.co.za/. Have a look at their site. Enjoy modding your Hilux :mrgreen:

Sifu-Lux

Since I got a nice pair of snap ring pliers from SWAMBO for Christmas, I decided to work off the Christmas over-indulgence this evening and carry on stripping the donor transfer case. I ended up buying a pair of 90 deg jaw ones as well since they were "only" R 145 ea :shock: Jonnesway flat...

Sifu-Lux

Merry Christmas to everyone ! Guess what, I got a pair of snap ring pliers from SWAMBO :)

And, I ate to much food.

Sifu-Lux

Welcome Romica !

I am glad you guy's from Romania have great Hilux's for exploring your country. I spent some time in Timisoara about 4 years ago and had some excellent Romanian wine in Arad.

Great country!

Sifu-Lux

Looking great Ewald ! You'll have to tell us if it is any quieter inside the cab with the new thick carpets and underfelt :)

Sifu-Lux

I took a drive down to the Paradise Beach 4x4 challenge today to have a look. Went in the BM as it is quicker and cheaper on fuel :lol: There was a reasonable turn-out, but mainly modifieds and super modified vehicles. Only two SFA's were there, and true to their legendary status one was a recovery ...

Sifu-Lux

Welcome Wyatt, nice truck!

Sifu-Lux

Check that the breather in the oil filler cap on the passenger side tappet cover is not blocked with anything. Maybe rinse it in paraffin. If its not that, then check your compression on all cylinders on the outside chance you are getting blow-by past the piston rings on a cylinder. I take it the en...

Sifu-Lux

chromoly Do you mean 'Chrome alloy'? :D Andy, it is chromoly, this was the material to have your BMX frame made from when I was a laaitjie. 41xx steel is a family of high-strength low-alloy steels (HSLA), as specified by the Society of Automotive Engineers (SAE). Alloying elements include chromium ...

Sifu-Lux

You just got to give this guy a view:

http://www.youtube.com/watch?v=3wPe7LDfdr4

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