Samurai 4.3L V6 project

[CoraZuki]

I have been getting ready for the 4.3 swap for the past year, but now I am finally getting started.  I have already rebuilt a 4.3L V6 that was pulled out of an 88 Astro van. 




After that was done I found a tranny/t-case that would work in the small Zuk.  I ended up getting a Ford top-loader with a Dana 18.  This gave me a manual 4-speed that I wanted, plus I can add an overdrive on the Dana 18 in the future.  This also gives me a very short tranny/t-case.  Believe it or not, but even with the engine set as far back as it can the Dana 18 will actually sit further forward than the stock t-case.









After that I got a Lakewood adapter to bolt the Ford top-loader to the Chevy 4.3.  I subbed up the tranny to the engine, without the flywheel or clutch, to make sure every thing would line up corectly.




I cut out the tranny tunnel to make room for the new tranny.




I tried to set the engine in to see how it fit, but the engine had to at too much of an angle to set it in.  So now I will be removing the front clip for easier access.

More to come...

[jeremp]

Keep the pics coming.

[Zuki-murai]

great "how to"   you shoul be more specific on the install, and keep the pics coming 

[madbob]

What bell housing did you use?  and what clutch and flywheel?  I have most of these parts, just haven't thought about putting them together untill now......

[CoraZuki]

What bell housing did you use?  and what clutch and flywheel?  I have most of these parts, just haven't thought about putting them together untill now......

The bell housing is a Lakewood that adapts a Chevy 350 to the Ford Top-Loader.  As you know the 4.3 is the same as a 350, so the bell housing works great. 

The clutch is a new, basic, clutch for the 4.3, but I don't remember what brand it is. 

The clutch disk is one for the Ford Top-Loader that is the same diameter and thickness as the clutch disk that came with the Chevy clutch.  The splines on the Ford tranny are different than on the Chevy.  That is why you need a Ford Clutch disk that matches the Chevy disk.  I got lucky because the friend who I bought the tranny from just happend to have the clutch that I needed.

I also got a Chevy to Ford pilot bearing from Lakewood.

I got the engine from a friend who already took it apart getting it ready for a project of his.  He sold the rig he was working on and then sold me the engine.  He had already picked up a flywheel for it and had it machined.  I'm not sure where he got it from, but I'm sure it's just a standard 4.3 flywheel.  I still have the flex plate for the auto that I will most likely sell.

I for got to take my camera with me today.  I finally got the font clip off.  I will post more pics as soon as I get them.

I'm not sure how the engine will fit in yet, it looks too big, but I know it can be done.

[1hybridzuk]

you might have to moddify the manifolds so they will clear the frame rails.  i used hedman headers on mine. still a tight squeeze but it gets the job done

I am also pretty sure that the stock steering is not going to work , mine didnt. you need a outboarded ifs toy box or similar.

I like your trans/tcase combination .....its really short. that will help the rear dshaft angles out!

[weed]

Im watching    Weed

[CoraZuki]

More about the tranny set up.

The adapter that bolts the Top-Loader to the Dana 18 is a Novak 200.  I called Novak to ask them some questions bout the adapter and found out that they do not make it any more.

I wanted to run a breather tube for the tranny but the Top-Loader only had a small hole for its breather.  So I drilled out the hole and used a bolt on valve stem.  I removed the valve stem core and it works great.



As you can see, the valve stem fits nicely.


You also might notice that the casting for the twin stick was busted.  Luckily a friend had given me a Dana 18 case a while back.  So it was a simple swap of parts to fix.



Last night I got the front clip off but I forgot my camera, so I will post more pics by the end of the week.

[SAMSZUK]

I love this build

[CoraZuki]

Its like trying to fit a square peg in a round hole.   

[jeremp]

What are you going to use for axles? Sammi, Yota, other?

[CoraZuki]

What are you going to use for axles? Sammi, Yota, other?

Other

I have a set of 79 Wagoner axles, Dana 44s.  I need to go through them and clean them up.  They need new seals, brakes, and a locker for the rear.  I will have to out board my front springs to fit the Dana 44.

I have a lot of work ahead me.   

[CoraZuki]

I got the front clip off the other day, and now I could slip the engine in to see how it will fit.  Its much tighter than I thought it would be.  I had to remove the exhaust manifolds to fit it in.  I could not get it where I wanted because I need to cut out some more of the old tranny cross member.  I will also need to cut out more of the passenger floor to make room for the t-case.   I want to do this without a body lift. 





Does anyone know if there is anyone around Kansas who can make custom exhaust manifolds?  Are they hard to make your self?

[jeremp]

You would ba amazed at how much more room you have to work with witha 1" or 2" body lift.

1" for me was an extreme differance and allowed me to place my engine in the bay. Since you have a different tranny and axles already a lift shouldn't affect too much else; except more room to place that big engine.

[CoraZuki]

I got more work done today.  After I did more cutting I set the engine back in and it fits much much better.  I hope to start building the engine and tranny mounts on Monday. 





After I pulled the engine back out I had to do more cutting.


A friend thought that a Toyota steering box would work because it sits on the out side of the frame and the pitman arm pionts foward.  This will give me room for the radiator that I have, plus it will give me power steering.