1uzfe into 2.4TD surf

[dannyboy77]

Thats similar to the one I made myself, I used a piece of 80mm stainless tube and welded it to a square plate, then cut out the centre with a jigsaw.
Dressed it up with a flap disc and sprayed it satin black.

cool was thinking of doing that but thought might be a bit tricky so for mere moral like myself it was easier to get one ready made!

Thanks for the info Dan, got the emails.

I will be able to fab flanges like that at work ok, cheers for link to pipe, I'm sure yoshie will be sourcing and fabbing the exhaust stuff for me as well as mounts etc.

not a problem if need anything more then give us a shout. here is a list of some sites that deal in unusual bits and bobs you need but think where the f#@k do i get that from

http://stores.shop.ebay.co.uk/Venair...Q_scZ1QQ_sopZ1

http://www.carbuildersolutions.co.uk/index.html

http://www.vehicle-wiring-products.e...e/homepage.php

[KERRSURF]

Cheers for the info mate, and the offer of help.
Great to see so many of these swaps getting decent write ups, helps those still to do it loads.

[hiroler]

how is it coming allong with the better weather should not be long now??

[dannyboy77]

well it has been on the road for a test drive but i have broken the front diff or it has coinsidentely broken during project. when i moved the folk to activate the front diff it is now knocking. just drained it and had a play and seems to be binding every revolution so think have buggered it also when spin 1 wheel one way the otehr should spin the other and it isnt initially then does and when spin both the same direction its binds at the same place every revolution so think f@#ked so can disengage it and drive it as 2WD annoying as wanted to test it a bala still could go but would get struck straight away

vince if you have any ideas much wlecome!

[BUSHWHACKER]

Is the vacuum lines still connected and functioning?

The collar inside the actuator, that slides across to lock the passenger side driveshaft/diff together, might be stuck and not engaging properly.
The passenger side driveshaft freewheels without turning the diff until the 4wd button is pressed.

[dannyboy77]

Is the vacuum lines still connected and functioning?

The collar inside the actuator, that slides across to lock the passenger side driveshaft/diff together, might be stuck and not engaging properly.
The passenger side driveshaft freewheels without turning the diff until the 4wd button is pressed.

the vacuum lines have gone i thought the point of having the folk in the perminant active position was to get rid of the vacuum? i was planning on having a H2 L4 box with no electrics so have the front diff active all the time by having moved the folk across and then when want 4WD shift to L4 to activate the front prop shaft and diff? i though the eletrics were only for H4 and the vacuum to move the folk across on the front diff. or have i got it totally wrong if so help!

[BUSHWHACKER]

Oops, didn't realise you had done the vacuum delete mod.

I still have the 'shift-on-the-fly' (H4) option on mine via the button on the transfer lever, it 'switches' the t/case to engage the front prop.

Do you have free-wheeling hubs fitted?

[dannyboy77]

no i dont have free wheeling hubs but i didnt think i needed them? i think the front diff has coinsidently buggered during the swap? just before i converted the TC went ther was a knocking noise rotary type when took front shaft off it didnt make the noise, this was driving in H2 as well so i got a TC off stormforce. so im not sure if during off roading on hard soil i got wind up and damaged my front diff and section of TC case????? as said when rotate the wheels in the same way it locked at the same place every revolution and there was a bit of sharred metal in the oil when drained just disengaged the collar on the front diff and doesnt make the noise now when drive

[dannyboy77]

oh just another question does the speedo work just off speed sensor 2? looking at the ECT diagram i see it is it jsut for gear change as i think it is working changing up and down gear but the the speedo doesnt work but i will double check i have wired it in!?

[BUSHWHACKER]

oh just another question does the speedo work just off speed sensor 2? looking at the ECT diagram i see it is it jsut for gear change as i think it is working changing up and down gear but the the speedo doesnt work but i will double check i have wired it in!?

Oh dear, sounds like the crown wheel could be missing a few teeth!

The two wire speed sensor, (#2) the one that you have to drill the T/case for, controls the gearchanges, the other sensor, (#1 three wires) the one with the plastic gear wheel on the end, is the one for the speedo.

The blue middle wire is earth, the green/red wire nearest the rear of the truck is the signal wire, (goes to the green/red wire in speedo). The third wire, black/orange needs 12v.

[dannyboy77]

Oh dear, sounds like the crown wheel could be missing a few teeth!

The two wire speed sensor, (#2) the one that you have to drill the T/case for, controls the gearchanges, the other sensor, (#1 three wires) the one with the plastic gear wheel on the end, is the one for the speedo.

The blue middle wire is earth, the green/red wire nearest the rear of the truck is the signal wire, (goes to the green/red wire in speedo). The third wire, black/orange needs 12v.

have you managed to get speed sensor one working then? had it on the road but forgot to wire up O/D so was doing about 35ish?? a gather in 3rd screaming down the road about 3000rpm. at the mo it sounds like a TVR have a 2" exhaust for each bank and 1 silencer on each so when idle its ok quite quiet but when reach 3000prm its a bit LOUDER!

[dannyboy77]

vince having trouble getting the OD to work. its changing gear OK from 1-3 at about 2500rpm but seems not to go into OD?? is it just a case of power from the gauge 10A to the the head up display then the OD wire from the head up display to the select lever and joining it with the OD wire from the ECU?

[BUSHWHACKER]

vince having trouble getting the OD to work. its changing gear OK from 1-3 at about 2500rpm but seems not to go into OD?? is it just a case of power from the gauge 10A to the the head up display then the OD wire from the head up display to the select lever and joining it with the OD wire from the ECU?

One side of the overdrive switch goes to the light in the dash cluster (plug B, pin 5, blue/yellow wire) then 'T' off from that to the ECU (plug 4, 26 pin, blue/yellow wire pin 3, OD2)

The other side of the switch goes to earth.

Have you got the speedo working yet?

[dannyboy77]

yeah i wired it up like the ECT & A/T indicator diagram shows and when press the OD off switch off on the shift lever the OD off light comes up on the dash so when press it on i thought the OD 4th gear would be engaged but when out in it it seems only to be in 3rd. does the gear change up happen at about 2500rpm?

i havent got the speedo working yet not too sure how to do it? can you give a quick explanation please

does the OD work by its self or does it need 19C SPD connected? or is that just for the speedo?

note just seen on diagram NCO+ & NCO- OD direct clutch speed sensor will have to see if that is connected??

[BUSHWHACKER]

yeah i wired it up like the ECT & A/T indicator diagram shows and when press the OD off switch off on the shift lever the OD off light comes up on the dash so when press it on i thought the OD 4th gear would be engaged but when out in it it seems only to be in 3rd. does the gear change up happen at about 2500rpm?

Overdrive is speed activated, not rpm. You need to be doing about 45mph for it to engage.

i havent got the speedo working yet not too sure how to do it? can you give a quick explanation please

The speed sensor/speedo drive on the back of the transfer case has three wires, if you've used the Surf's wire colours, it's;
Black/orange = 12v.
Green (it may be blue, can't tell) = Earth.
Green/red = signal wire, connect to pin 8, plug A on cluster. (yellow wire)

The Violet/white wire (plug A pin 10 on cluster, goes to ECU (SPD)

does the OD work by its self or does it need 19C SPD connected? or is that just for the speedo?

Just for speedo.

note just seen on diagram NCO+ & NCO- OD direct clutch speed sensor will have to see if that is connected??

They should be already connected as they're part of the loom and not touched.