non suzuki swap

[zooky]

The vibration is only bad in gear at a stop, you shouldnt have that problem with the 5-speed, just the normal diesel vibration. I think you could get the drivers side mount to work, I just wanted to use the softer VW mount and I made it that way due to clearance issues with the lower radiator hose.
Post the link when you get it going, I'd like to see your project.

[Flash319]

Here is the link to my build.  http://www.yotatech.com/f116/vw-diesel-build-up-135203/#post50725584.  Let me know how your truck is doing.

[zooky]

thats going to be a great build up, post lots of pics!
I havent dug into the transmission swap yet, I was getting laid off and didnt know what was going to happen with me. I pulled off the bed instead to clean the frame, it cleaned up well and is in mint shape. The bed has some issues but should last a few more years. I got a new job so I need to throw the bed back on and get that swap done. Good luck with your swap, looking forward to your progress

[vwzzuk]

Just a heads up...

Make sure your adapter plate is parallel and is also lined up precisely with the input shaft/bearing/bushing of the tranny. When the early suzuki diesel kits came out, one of the vendors had repeated transmission failures and traced the problem back to the steel plate not being parallel. I can't remember if line-up dowels were an issue or not. They did however, end up blanchard grinding all their plates to get them flat to work. No problems after that.

Keep up the good work!

[zooky]

just a post for a host

[zooky]

boy, the diesel section really slowed down, thought I would post some useless chit-chat.
Saw my first junkyard 1.6TD, NEVER saw one in a junkyard before. I wanted to snag it but I just dont have the time or room for more stuff, it was still in an '86 Jetta and the tags had '95 stickers on it. It was crusty looking. I did score the injector pump, it was sitting on the front seat so I grabbed it for a spare.

I decided to swap the automatic out of the truck. I think I could have got it working better if I wanted to mess around with it more but screw it. I have most of what I need to do the conversion and I started on it today. I think the biggest PITA is going to be the exhaust, it crosses under the trans and has to be removed to get the trans out. I paid a small fortune to get it installed last summer and dont want to cut it up. I am also concerned the clutch fork might be in the way, then I will have to redo the exhaust. If thats the case I will swap the fuel tank to the other side and run the exhaust strait back. The rear end  ratio will be a little low with the 5-speed, the 2wd has a few higher ratios that I could swap out, I think there is a 3.08 that came in the 4-speeds. That will lower my RPM's and give me better mileage, I have to do some research and figure a good cruising RPM and what ratio would get me there. Thats all I have to add, nothing interesting. I'll update this once I get somewhere...

[Flash319]

Hey Zook,
I have a 5 speed in my truck (G58) and have 4:10's.  I am at 3000rpm at 70 with 31inch tires.  If that means anything to you.  The 2wd is lighter then my 4wd so they can not compare plus you are running smaller tires.  You will like the manual much better though.  I have an auto 4runner and I hate it.

[zooky]

the 5-speed swap is going pretty good, I have to wait for Jeff (Acme) to get back from vacation to get some parts. I have the clutch pedal and master cylinder installed, the transmission is installed so I can check clearances and determine where I need to drill the tunnel for the shifter. As expected, my exhaust wasn't going to work. I cant go down then across due to the clutch fork being in the way, I had to go behind the head. I ordered Acme's down pipe (sami/tracker application) and unfortunately it wouldn't work in the Toyota. Its a nice piece and would have saved me ALOT of time and aggravation and I would highly recommend it to make your life easier. I ended up picking up a bunch of Hooker mandrel bent U and J pipes, they have a tight enough bend radius that I was able to snake it between the head and firewall, just under the coolant port on the head. I have about a 1/4" clearance from everything and I hope the header wrap will keep it cool enough so I dont have problems. I wish I could weld stainless so I would never have to worry about it again.
 I hope to have it ready to go when Jeff gets back so when I get the flywheel I can put it all together and be done with the swap. I need to lengthen the driveshaft a few inches and rework the trans mount, other then that it should be done.

[Flash319]

Could you just get a spacer for the driveshaft or is it more the an inch or so?  I could make you one if that would work.  Save making a new shaft.

[zooky]

its a slip yoke going into the transmission and a cushin block on the other end (2 piece driveshaft), but thanks for the offer. I'll try to find a longer one and shorten it, I got a feeling I will get bent over if I have a driveshaft place lengthen it. I need to figure out my gearing also eventually.

[zooky]

wow, I work slow! I havent touched this much lately. I have the 5-speed mounted in there. The trans mount was easier then I thought, my first design was way more complicated then it needed to be but I ended up going with something simple. I just finished my header pipe, I had a tough time with that. The toyota firewall was tighter then a sami's and I seemed to have clearance problems everywhere. I need to get this thing going so I hope to update this more often.

[zooky]

still plugging away at this. Just got the exhaust done, came out nice but I would hate to have to do it again. The 5-speed swap is done, just need to get the driveshaft lengthened. I have a bunch of details to finish up but all the bigger jobs are done. I think the end is in sight mechanically, one I get it driviable I can work on the cosmetics. Yay

[zooky]

another update. Got the driveshaft lengthened and installed and worked off most of the minor details but still have some to go. I started it for the first time in 1.5 years and since the 5-speed install and it fired right up. Runs real smooth, I think this because of the heavy toyota flywheel. The nasty vibration I had with the automatic is gone! I have some loose ends to tie up before I can take it for a test drive.
I could not stand to put the rusty bed back on the cleaned up frame. I found a home made flat bed on craigslist, not a big fan of flat beds but this on is well made and looks pretty good I guess. Its heavy, I had installed 1 ton springs so the rear sat a little high but this bed leveled the truck back out. The flat bed was built for an extended cab toyota so I have to drill a few new mount holes and remount the gas filler bracket.
I am on the lookout for a 3.08 rear axle to bring the highway RPM's down for better MPG's. I dont want to go with a taller tire, I'll stick with the stock 25 inchers.
Found another pic of engine bay:

[zooky]

here is a pic of the truck:

[350TacoZilla]

dude way cool project and progress, pity not alot of people chime in the diesel section...

I had swapped a 2.2L  1L toyota diesel into a 89 4x4 toy couple years ago. very fun to have small diesel truck.. one suggestion put stacks on it... people made fun of my stacks on a gas truck till i started it and smoke puffed out