Hilux Rebuild

robvan87 · Post by **robvan87** » Wed Apr 17, 2013 9:38 pm

4 Months ago I took on the extremely daring task of rebuilding my Lux from ground up. Never thought that it would be this much work. Thought I would share some picks of the past few months progress with my fellow hilux fans.

The before

She was in my opinion not bad looking but had a few 'brandewyn vlekke' which irritated me and a few rust marks etc etc

The Strip

Differential overhaul

The transplant

Chassis treatment

More photos comming soon........

robvan87 · Post by **robvan87** » Wed Apr 17, 2013 9:43 pm

Photos and captions dont match... ooops. First time posting from tapatalk... sorry guys

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Froll · Post by **Froll** » Thu Apr 18, 2013 9:55 pm

Good looking truck, waiting for more pics. Looks like a job well done so far.

GeorgeJvR · Post by **GeorgeJvR** » Fri Apr 19, 2013 8:24 am

Froll wrote:Good looking truck, waiting for more pics. Looks like a job well done so far.

Post by **Mud Dog** » Fri Apr 19, 2013 10:34 pm

She was still looking pretty good before you started, Robert. Gonna look awesome once you're done!!

That Lexus transplant will make a big difference as well!

robvan87 · Post by **robvan87** » Sun Apr 21, 2013 7:25 pm

Thanks guys. The build has been quiet a test of faith, alot of swearing and late nights:mrgreen:
. When I removed the rear diff centre portion I got a lekker surprise. The spider gears had a few teeth missing and the local dentist 'gearmax' had to help a bit. Still waiting on the return of the diff the guys there a testing my patience at the moment, but I now know why I drive a hilux. The diff started with the shakes at my last extreme 4x4 trip, after that I still drove to sodwana towing a trailer and the diff just went on. Now thats Hilux reliabilty!!!

Here are a few more pics

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Post by **Mud Dog** » Sun Apr 21, 2013 11:51 pm

Looking good so far!

(I liked the original colour more.

)

TOYODA · Post by **TOYODA** » Mon Apr 22, 2013 7:49 am

Looks good, can't wait to see the finished vehicle!

robvan87 · Post by **robvan87** » Mon Apr 22, 2013 9:07 pm

Cranked the motor this evening. Everything sounds good so far. Still need to fit the fuel tank and 10mm fuel hose before she can start ticking. Cant wait now!!!:razz::-D

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robvan87 · Post by **robvan87** » Thu Apr 25, 2013 8:24 pm

The motor started yesterday evening and gave me goose bumps, what a great feeling. Now i need to tidy the engine bay and start putting back all the bits and peices filling my garage at the moment. Here are a few pics of the motor. Oh and fitted xenon headlights....

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robvan87 · Post by **robvan87** » Thu Apr 25, 2013 8:27 pm

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robvan87 · Post by **robvan87** » Sat Apr 27, 2013 8:22 pm

Quick question to all the clever guys on the forum. Are fortuner seats and vigo seats the same? Rhe front ones? I fitted ivory leather seats today which were from a unfortunate fortuner, but it was a hell of a strugle compared to the post from another forum member who fitted vigo seats. I must say it was worth the effort but had to change the whole mounting structure.

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Post by **Baasvark** » Sat Apr 27, 2013 8:35 pm

Hey Rob, looking good!

robvan87 · Post by **robvan87** » Sat Apr 27, 2013 8:41 pm

Thanks baasvark, cant wait to get it done now:-D

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ForYota · Post by **ForYota** » Mon Apr 29, 2013 1:14 pm

robvan87 wrote:Quick question to all the clever guys on the forum. Are fortuner seats and vigo seats the same? Rhe front ones? I fitted ivory leather seats today which were from a unfortunate fortuner, but it was a hell of a strugle compared to the post from another forum member who fitted vigo seats. I must say it was worth the effort but had to change the whole mounting structure.

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Hi,

I also fitted the Vigo seats and believe me it was not any joy, however happy now that it is done!

robvan87 · Post by **robvan87** » Sun May 12, 2013 7:17 pm

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Hoppy · Post by **Hoppy** » Sun May 12, 2013 7:36 pm

The "chop job" on the IFS doesn't look good, i must give him a few tips on the loadbox

Jaco Versfeld · Post by **Jaco Versfeld** » Mon May 13, 2013 12:28 pm

Don't you have height problems with the Vigo seats. I have heard that the bullnose seats are too high?

ForYota wrote:
robvan87 wrote:Quick question to all the clever guys on the forum. Are fortuner seats and vigo seats the same? Rhe front ones? I fitted ivory leather seats today which were from a unfortunate fortuner, but it was a hell of a strugle compared to the post from another forum member who fitted vigo seats. I must say it was worth the effort but had to change the whole mounting structure.

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Hi,

I also fitted the Vigo seats and believe me it was not any joy, however happy now that it is done!

ForYota · Post by **ForYota** » Mon May 13, 2013 12:43 pm

Hi Jaco, dont know who you reffering to here but let me answer anyway, should there be more peeps that would consider this..

Would I fit Vigo seats to an SFA again - NO

Reason being a couple of things, the Vigo's roof are much Highter than the SFA's
So you have about 40mm of head to roof clearence, not suffient, especially with a farm hat or cap on your head..
When you hit a small ditch in the road, your stiffy SFA bump once, and you actually bump twice, as if the seats have its own springs inside of them.. Ok Other than that its still much better than the long fixed seat it had in origanally, sits much more cumfortable and you actually get to drive the vehicle alone, not like when your partner stretches or leans backwards you "go" with them...

BUT this is only me, being 1.9m tall and all, my wive on the other hand actually now enjoy's driving as she couldn't do so with the old seats...

Hope this helps

Jaco Versfeld · Post by **Jaco Versfeld** » Mon May 13, 2013 1:01 pm

Thanks for the reply.

I bought Mufasa with Condor seats. I am 1.87 m, and with the Condor seats, I had to look through the blue strip at the top of the windscreen. Driving to Namibia literally became a pain in the neck, especially when driving at night.

My mission started to find original SFA bucket seats. I found a pair (at a premium, the guy saw me coming), and thought it is a bolt on exercise - big mistake. My father-in-law helped me modifying two brackets on each seat in order for them to fit. I still need to sort out the safety belts in the front though. (Luckily I have a pair of SFA Raider belts, fitted the rear ones already). The seat belts of the Raider fits to the body, between the two seats, where the bench have the seatbelt "stalks" coming from behind. I assume the stalks are fixed to the Vigo seats?

ForYota wrote:Hi Jaco, dont know who you reffering to here but let me answer anyway, should there be more peeps that would consider this..

Would I fit Vigo seats to an SFA again - NO

Reason being a couple of things, the Vigo's roof are much Highter than the SFA's
So you have about 40mm of head to roof clearence, not suffient, especially with a farm hat or cap on your head..
When you hit a small ditch in the road, your stiffy SFA bump once, and you actually bump twice, as if the seats have its own springs inside of them.. Ok Other than that its still much better than the long fixed seat it had in origanally, sits much more cumfortable and you actually get to drive the vehicle alone, not like when your partner stretches or leans backwards you "go" with them...

BUT this is only me, being 1.9m tall and all, my wive on the other hand actually now enjoy's driving as she couldn't do so with the old seats...

Hope this helps

ForYota · Post by **ForYota** » Mon May 13, 2013 1:07 pm

It is fitted to the seats indeed..

Still looking for belts though.. At least this exercise got me seatbelts at the back now, as it never came out wilth belts in the back, but threaded holes for the clips etc

Anyhow, Maybe get a sunroof

robvan87 · Post by **robvan87** » Mon May 13, 2013 7:53 pm

The fortuner seats sit very high, but comfortable. You do however have the adjusting knob on the sit that you can lower a bit. Havent been out driving with it just yet, will let you know how the offroad driving goes.

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ink · Post by **ink** » Mon May 13, 2013 8:02 pm

The lexus looks good....the power steering presure pipe is a bad one hey

robvan87 · Post by **robvan87** » Mon May 13, 2013 8:07 pm

I am more worried about the air intake, with the 50mm bodylift the brake lines are in the middke of the intake which is a bit of a brain teaser!!!

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Andre du preez · Post by **Andre du preez** » Tue May 14, 2013 3:12 pm

Baie cool!!

GeorgeJvR · Post by **GeorgeJvR** » Tue May 14, 2013 3:19 pm

robvan87 wrote:I am more worried about the air intake, with the 50mm bodylift the brake lines are in the middke of the intake which is a bit of a brain teaser!!!

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I read somewhere you can turn the intake 180degrees by unbolting the whole intake, or something like this ask around maybe someone can help you or give you more details...

ink · Post by **ink** » Tue May 14, 2013 3:49 pm

Need to turn the feul rails everything but yes it can be done

ink · Post by **ink** » Tue May 14, 2013 3:54 pm

No body lift on mine, just had a look it must klear. If the. Intake pipe is a 90' bend

ink · Post by **ink** » Tue May 14, 2013 3:57 pm

Pic 1

ink · Post by **ink** » Tue May 14, 2013 3:58 pm

Beter pic

robvan87 · Post by **robvan87** » Wed May 15, 2013 8:29 am

Thanks for rellies guys, Ink, my front brake line on my brake master exits the same way as the rear one, I will see if I can get on that exits on top. But bu the looks of it it should clear. Otherwise I can get a 90degrees bend for the brake line. I see you reduced the intake size immediatley after the intake from 80 to 67. Do you find that motor chokes a bit or is all well on the breathing?

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Hoppy · Post by **Hoppy** » Wed May 15, 2013 8:36 am

Why don't you just rotate the inlet manifold top bu 180deg, then everything fits so much better and you can fit a decent donaldson type air cleaner, those cones only keeps the rocks out.

ink · Post by **ink** » Wed May 15, 2013 9:25 am

Mine breaths fine , but want to turn around to go to standard air filter box to a snorkel

robvan87 · Post by **robvan87** » Wed May 15, 2013 11:54 am

Ink, one more question, your throttle body is much shorter than mine, it seems as if the second butterfly fly valve is missing. Or have you removed it?

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robvan87 · Post by **robvan87** » Wed May 15, 2013 11:57 am

Hi hoppy, i dont really want to turn the intake 180, it aint gonna look good. If all else fails i will cnc engineer a adapter for the intake wich will force it 45 degrees. That will ensure a safe route pass the master cylinder.

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robvan87 · Post by **robvan87** » Wed May 22, 2013 8:17 pm

Ok, progress thus far. Everything is done except the air intake. Took it for a drive on sunday and stripped the gearbox. TT Joburg supplied bellhousing that is 3mm out. Yipeeee. Another question, what transmissions do we have in our hiluxes, w56 or G52, will i be able to buy a new box (4x2) and transplant the rear casing or will this not be possible? Toyota quoted R4800 for the cluster shaft and the input shaft. I can get a used box for R6000. Anyone interested in a transfer case?

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GeorgeJvR · Post by **GeorgeJvR** » Thu May 23, 2013 7:25 am

Fit a KZ TE Box.

robvan87 · Post by **robvan87** » Thu May 23, 2013 7:30 am

They are pretty hard to come by George. I can get a 3rz gearbox and transfer case? But i dont know if the ratios wil suffice

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GeorgeJvR · Post by **GeorgeJvR** » Thu May 23, 2013 7:51 am

I may be wrong but the 2.7 one is not that much stronger than the 22R / 4Y gearbox.
You should be able to find one at a scrapyard
http://www.gumtree.co.za/cp-replacement ... redAd=true" onclick="window.open(this.href);return false;
May be these guys can help, just saw the ad this morning.

robvan87 · Post by **robvan87** » Thu May 23, 2013 5:39 pm

Thanks for the link George, i appreciate. Even if they are able to help I am go8ng to pay well over a grand for shipping. I am convinced that the 4y gearbox is strong enough for the v8 within reason, ie dont abuse too much. If you wikipedia the w series gearbox they were usedbin the sc300 lexus applications as well. The 2jz motor, 168kw which is not very far from the 198kw of the v8. Dont if my reasoning is dumb but I am sure that with the right bellhousing the 4y motor should at least last more than 10km driving below 4000rpm. Not saying that the 4y gearbox is unbreakable but alot cheaper than a second hand kz-te box

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ink · Post by **ink** » Thu May 23, 2013 6:54 pm

Sorry for the late reply , yes only one throttle body . I'm also on manual used my standard gearbox from the old 2.8diesel not sure what it is called, got a belhousing from fana at R4k. And it works fine, know Murray also got he's from fanna and he also don't have problems. I'm burning up my standard 33"bfs on the tar.......I'm running a quantum clutch and so far all good....

robvan87 · Post by **robvan87** » Thu May 23, 2013 7:13 pm

No probs ink. There is a hilux here in town which was the first in the lowveld to have a 8 installed. That was 10 years ago, that hilux has run approx 80 000 with the conversion doing 4x4 challenges etc, and the only part he has lost was a diff. So I am pretty confident in the gearbox. If you are going to abuse it you will break it. The guy at TT joburg admitted to the bellhousings being faulty and had absolutely no problem in exchanging them. Unfortunatly this incident is costing me a few cash rands.....

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ink · Post by **ink** » Thu May 23, 2013 7:18 pm

Love the manual with the 8, here are a lot here running well. Your air intake sorted yet

robvan87 · Post by **robvan87** » Thu May 23, 2013 7:24 pm

Nope not yet, But i have concocted a plan. Found the shafts for the gearbox localy for 2450 which is a lot better than family price at toyota....

so the plan at thr moment is to buy the shafts fix my box fill it with oil store in the garage. Buy the other box and go to mozambique....

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AM Racing · Post by **AM Racing** » Thu May 23, 2013 8:58 pm

I also got my bellhousing from TT and have a whine in my gearbox now which was NOT there before. Gonna call them in the morning! Nice build!

robvan87 · Post by **robvan87** » Fri May 24, 2013 3:07 pm

Get the correct bellhousing asap... that box is gonna strip..!!!

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AM Racing · Post by **AM Racing** » Sat May 25, 2013 12:08 pm

robvan87 · Post by **robvan87** » Tue May 28, 2013 6:54 pm

Okay ek het nou die naweek die ou nuwe ratkas ingesit, maar vierde rat spring nog steeds uit. Dink julle dis per toeval, want die nuwe bellowing het ingegly soos 'n droom. Miskien 'n synchro ring wat moeilikheid maak? Enige iemand ander raad?

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robvan87 · Post by **robvan87** » Sat Jun 01, 2013 4:46 pm

Anyone know what lexus alternator IC'S go for?

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vanthev8man · Post by **vanthev8man** » Sat Jun 01, 2013 5:04 pm

robert,

uitspring het niks met syncros te doen nie - dis bloot slytasie.
selfs al is die bellhousing uit lyn uit -soos ek aflei uit vorige gesprekke- sal dit steeds nie 4de laat spring nie.

robvan87 · Post by **robvan87** » Sat Jun 01, 2013 5:10 pm

As jy sê dis sluitasie , hoe sal 'n mens te werk gaan om dit reg te kry, dankie vir die terugvoering.

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vanthev8man · Post by **vanthev8man** » Sat Jun 01, 2013 5:43 pm

jy is welkom,

jou 4de rat in meeste ratkaste is letterlik die "input shaft".
hy word geskakel met n "hub & sleeve" en dis gewoontlik die sleeve wat gesluit is en ook die "dogs" op daardie spesifieke rat wat die uitspring veroorsaak.
dit kan(suksesvol)herstel word,(of vervang)maar ratkas moet uitmekaar gehaal word.

robvan87 · Post by **robvan87** » Sat Jun 01, 2013 5:48 pm

Ek is al 'n bietjie gat vol vir die ratkas insit en uithaal storie. Is dit skadelik gaan ek weer die ratkas kan breek as ek dit nie uitsorteer nie?

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vanthev8man · Post by **vanthev8man** » Mon Jun 03, 2013 9:53 am

nee wat-dis maar net lastig!

AM Racing · Post by **AM Racing** » Mon Jun 03, 2013 9:56 am

Just spoke to the guys at TT and they admit there was a faulty batch of bellhousings and they will be replacing mine as soon as I get it up to them

robvan87 · Post by **robvan87** » Tue Jun 10, 2014 8:54 pm

Just realized that it's been a year and a half since my lux has been on the road...! Not a nice feeling! Autobox will be installed next week. Hopefully that will be the end of all the problema

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Post by **Mud Dog** » Tue Jun 10, 2014 9:04 pm

Was already thinking that you'd abandoned the project!

robvan87 · Post by **robvan87** » Tue Jun 10, 2014 10:28 pm

Nope.. It's just been a hell of a ride! Nothing worked out as it should have...

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Striker · Post by **Striker** » Thu Jun 12, 2014 1:12 pm

This is what I did for my intake.

robvan87 · Post by **robvan87** » Thu Jun 12, 2014 2:12 pm

Got mine sorted with the same 90 bend, but my brake master doesn't have an upright outlet like yours, both outlets face to the right (to the engine). So I had fittings made up with braded break hoses. The bend still touches the brake line but I am sure it will hold.

Just another question. The Donaldson filter has a 63mm diameter on all the pipes. Will this not decrease performance?

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