Popular Post Jeffs_Emporium Posted February 27, 2021 Popular Post Share Posted February 27, 2021 For over two years I have lusted after this van. Previous owner had cooked it and didn't ever show up for repair bill (4 speed gearbox, 4.6 diff ratio, no overflow/recovery fitted from factory) Luckily the mechanic put the registration on hold when he saw it was about to lapse. In September 2020 I was finally able to secure it. 160,000kms, 5k engine, L40 4 speed column shift. 18 Quote Link to comment Share on other sites More sharing options...
Jeffs_Emporium Posted February 27, 2021 Author Share Posted February 27, 2021 First on the job list was to make it be able to sit on 100 km/h without boiling over so I located a 3.9 ratio E series replacement. From research only the high spec diesel and diesel turbo and the ym30/40g come with a tachometer in the dash (ive yet to see one in nz) so I've had to use an online calculator on blocklayer.com to see what's going on. At 100km/h with the 165/80/13 and 4.6 ratio it was doing 4100rpm... Changing to 3.9 sees it reduced to 3470rpm. I've also acquired a rebuilt g52 column shift 5 speed which will drop it down to 3050rpm 9 Quote Link to comment Share on other sites More sharing options...
Popular Post Jeffs_Emporium Posted February 27, 2021 Author Popular Post Share Posted February 27, 2021 Changing from the L40 to g52 will also require hydraulic clutch conversion, shorter driveshaft and a different gearbox crossmember which I've been lucky enough to peice together from a ym36 and cm36 at pickapart. it also requires a lot/all of the dash out to change the brake reservoir to the one pictured with extra provision for the clutch master cylinder 11 Quote Link to comment Share on other sites More sharing options...
Popular Post Jeffs_Emporium Posted February 27, 2021 Author Popular Post Share Posted February 27, 2021 3050rpm is not very much for a little 5k on the motorway but it's future proofing for smaller tyres and an engine swap with a bit more torque. I found a package on trademe for a 16V bigport 4age that came with some extras (a van load) I could sell off to get some of my funds back The more I looked through everything once it was home the better it got, the t50 saw me 80% reimbursed within and hour of listing. Then there was 4agze coil packs and CAS, two spare heads, two spare blocks, multiple looms and ecu. Best of all it has also been predominantly rwd converted already for use in a kp60 (has some kp60 custom engine mounts already attached which I'm thinking may work?) Further inspection of the engine it has a new cambelt and rwd waterpump, new frost plugs, a MLS headgasket and taking off the cam covers shows me it hasn't been started since having this work done. 16 Quote Link to comment Share on other sites More sharing options...
Popular Post Jeffs_Emporium Posted February 27, 2021 Author Popular Post Share Posted February 27, 2021 Since I had all of my money set aside for an engine and some returned I decided to use that for upgrades. I located a pair of unused weber dcoe40, a twin carb manifold, a Sq engineering rear water outlet (heater core in van isn't currently connected so wanted the option to block off untill I source another) and an alternator relocation bracket which puts it on same side as the 5k to utilize the factory wiring 19 2 Quote Link to comment Share on other sites More sharing options...
Popular Post Jeffs_Emporium Posted February 27, 2021 Author Popular Post Share Posted February 27, 2021 I picked up a set of Impul Pro mesh in 14x6.5 which had the centres blasted and painted and new stainless fasteners with some 185/60/14s fitted. Auckland leaf spring repairs reset the rear springs for a 3" drop and front torsions re-indexed to suit 14 1 Quote Link to comment Share on other sites More sharing options...
Popular Post Jeffs_Emporium Posted February 27, 2021 Author Popular Post Share Posted February 27, 2021 I use this van every day for my small residential building company so when I saw this plate pop up I felt it fitted perfectly. We carry everything you need to build a house in this box and somehow it all fits like some weird game of tetris at the end of each day 27 2 Quote Link to comment Share on other sites More sharing options...
Jeffs_Emporium Posted March 1, 2021 Author Share Posted March 1, 2021 I usually go through quite a few wheels before settling on something but these will be something I will keep and a bit of a long term project to eventually end up on the van. 13x6j 1983 Yokohama B.R.X (Boy Racer eXciting) BR-1 As you can see the condition is pretty poor with some really bad pitting on the centres. Pine engineering will be on refurb duties along with potentially widening the pair with dinged front lips. A bit torn as the 14s look the right size and are practical and don't need a huge sidewall for ground clearance so it's likely they will remain for daily duties with the refurbished 13s for collecting various building awards. That brings us pretty much up to date. My original plan was to collect all the bits and swap engine and gearbox at same time but I think after seeing how involved the gearbox swap and converting to hydraulic clutch will be I will undertake that first so the project isn't too overwhelming. The kr42 which use a 7k and g52 seem to pop up at pickapart quite often so will snag a bellhousing and clutch fork from that to get me hooked up for the mean time Can anyone on here comment on use of the nz made hyperpak setup to control spark for the 4age? They seem to be the preferred method than the 4k distributor adapter. 2 Quote Link to comment Share on other sites More sharing options...
Popular Post Jeffs_Emporium Posted March 1, 2021 Author Popular Post Share Posted March 1, 2021 turquoise in place of the red in the centres is on the cards for sure 21 Quote Link to comment Share on other sites More sharing options...
Popular Post Jeffs_Emporium Posted April 6, 2021 Author Popular Post Share Posted April 6, 2021 4age - w55/g52 bellhousing popped up for cheap on marketplace that I've secured. Need to figure out which flywheel ( I have a gze one and a NA one) to use and sort a clutch The 13s are currently at Pine Engineering getting some much needed love. 11 Quote Link to comment Share on other sites More sharing options...
Jeffs_Emporium Posted April 14, 2021 Author Share Posted April 14, 2021 Flywheel was cleaned up and resurfaced. Went with the bigger 4agze 230mm flywheel, just need to track down a clutch to work with the g52 box. Shopping list to get this done: -Hyperpak spark module -exhaust manifold of sorts (potentially coby) -clutch kit, fork, slave, hardline -setup linkage for carbs -flywheel bolts -viscous or electric fan -hope that engine mounts work 8 Quote Link to comment Share on other sites More sharing options...
Popular Post Jeffs_Emporium Posted July 8, 2021 Author Popular Post Share Posted July 8, 2021 Additional van arrived today so I can begin the engine and box swap. Wof recheck tomorrow then the 5k is coming out Saturday. I've got two weeks untill my garaged car comes home from Christchurch so at a minimum the engine and box need to be in so it's not blocking access. 11 Quote Link to comment Share on other sites More sharing options...
Popular Post Jeffs_Emporium Posted July 8, 2021 Author Popular Post Share Posted July 8, 2021 Approved 24 1 Quote Link to comment Share on other sites More sharing options...
Jeffs_Emporium Posted July 10, 2021 Author Share Posted July 10, 2021 New genuine clutch fork, release bearing carrier with clips and rubber boot arrived. $100 including post via amayama Heavy duty ae86 clutch is on order from Japrace in Christchurch also 7 Quote Link to comment Share on other sites More sharing options...
Jeffs_Emporium Posted July 10, 2021 Author Share Posted July 10, 2021 Have the gearbox removed. Already something isn't as its supposed to be and I'm not sure why. for starters the gearbox crossmember I took from a liteace at pickapart lines up with support members on body but two holes are missing in body, (would need to drill and weld in some crush tubes) looking at the crossmember from box I pulled from mine it would work on g52 but why is my driveshaft so short... 3 Quote Link to comment Share on other sites More sharing options...
Jeffs_Emporium Posted July 10, 2021 Author Share Posted July 10, 2021 Lift van up and take passenger wheel off to slide crane in then it was pretty straight forward 6 Quote Link to comment Share on other sites More sharing options...
Jeffs_Emporium Posted July 10, 2021 Author Share Posted July 10, 2021 Very crusty engine room 9 Quote Link to comment Share on other sites More sharing options...
Jeffs_Emporium Posted July 10, 2021 Author Share Posted July 10, 2021 Have been researching suitable fuel pump for the webers and came across this link https://www.racetep.com/manufacturer/carbs-and-injection/weber/electric-fuel-pumps.html I don't know how much of this is true but it fooled me enough to order the Carter Fuel Pump mentioned from rock auto ($110 nzd delivered) 8 Quote Link to comment Share on other sites More sharing options...
Popular Post Jeffs_Emporium Posted July 11, 2021 Author Popular Post Share Posted July 11, 2021 Put old crossmember on g52, soldered the old reverse switch plug on and transfered the speedo cog. put it in the hole and attached to old mounting holes and I'm in the ballpark of +/-5mm for the engine mounts lining up measuring from bellhousing face! Slid the shorter driveshaft in and measured gearbox seal shield back to diff. I need 695mm, shorter shift I have is 568mm and longer 740mm. Looking at the other gearbox crossmember it shifts the box further back but if my engine mounts line up the lesser of two evils is definitely dropping driveshaft off to get shortened than making engine mounts and needing to drill and weld crush tubes into chassis. One shifter linkage bolts straight up and other I possibly need to trim and fit a socket/tierod fitting to end. Looks easy 14 Quote Link to comment Share on other sites More sharing options...
Jeffs_Emporium Posted July 11, 2021 Author Share Posted July 11, 2021 Had a look through some old notes and I measured a yr25 driveshaft with g52 and e series diff at 625mm earlier in the year at pickapart. Since I measured this from gearbox dust cover outer chances are that was the shaft I need 5 Quote Link to comment Share on other sites More sharing options...
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