Outer Limits 4x4 Board

hey guys..

just after some feedback on this upgrade.

I've got all the bits required now.. and I am considering taking the 40 off the road for a week to get this done..

of those who have done this mod, do you think its a relatively easy job for 1 person to do over the week? I've rebuilt the front knuckles before, done various other bits with steering (swap over std and power steering)..

are there any "gotcha's" that i'm likely to encounter?? also are there any special tools required to do the swap?

I have most things but i don't have a press.. will this be a problem?

any comments are welcome..

cheers,

Andrew

Just put 80 steering box, and 55 column with v8 commodore pump, to 80 diffs, on my 40.
took abit. but i moved the diff forward a fair bit.
i would look to have it all mocked up before you take it off the road.
the shaft length is one thing to check. and clearance off the chassis depending on box location.

but in theory id say yeah you can do it.

i did mine in a weekend by myself, so you should be fine.

the two "gotcha's" i found were you might have to move your shock mount,

and you need to move your battery to somewhere else.

what intermediate shaft are you running?

bad_religion_au wrote:i did mine in a weekend by myself, so you should be fine.

the two "gotcha's" i found were you might have to move your shock mount,

and you need to move your battery to somewhere else.

what intermediate shaft are you running?

Thats good to hear Adam. I have my 2nd battery above that shock mount so I dont mind relocating that as the main battery is on the opposite side.

I was following Toohey's shopping list from the Cruiser Bible ( http://www.outerlimits4x4.com/viewtopic.php?t=46390 ) and got a intermediate shaft from a 75, 80 cushion joint.. I haven't yet had a chance to dummy up the positioning but from the look of things in Tooheys article it should be fine. I know ray185 used a MWB intermediate shaft for his (to a 60 column).. but I guess I wont know until I get it mocked up.

shorty_f0rty wrote:

bad_religion_au wrote:i did mine in a weekend by myself, so you should be fine.

the two "gotcha's" i found were you might have to move your shock mount,

and you need to move your battery to somewhere else.

what intermediate shaft are you running?

Thats good to hear Adam. I have my 2nd battery above that shock mount so I dont mind relocating that as the main battery is on the opposite side.

I was following Toohey's shopping list from the Cruiser Bible ( http://www.outerlimits4x4.com/viewtopic.php?t=46390 ) and got a intermediate shaft from a 75, 80 cushion joint.. I haven't yet had a chance to dummy up the positioning but from the look of things in Tooheys article it should be fine. I know ray185 used a MWB intermediate shaft for his (to a 60 column).. but I guess I wont know until I get it mocked up.

yep, should work a treat, that's the way i did mine. don't forget that if it's too long, you can shorten it by drilling out the plastic bung and "tapping" the shaft with a hammer because they are collapseable columns.

forgot about the Bj 42 dual batteries.

another thing to think about is, are you going to want to push your front diff forward at all? if so, now is the time to do it, as you have free reign as to where to mount the power steering box, but once it's mounted, your limited as to how far to move the front diff forward.

bad_religion_au wrote:

shorty_f0rty wrote:

bad_religion_au wrote:i did mine in a weekend by myself, so you should be fine.

the two "gotcha's" i found were you might have to move your shock mount,

and you need to move your battery to somewhere else.

what intermediate shaft are you running?

Thats good to hear Adam. I have my 2nd battery above that shock mount so I dont mind relocating that as the main battery is on the opposite side.

I was following Toohey's shopping list from the Cruiser Bible ( http://www.outerlimits4x4.com/viewtopic.php?t=46390 ) and got a intermediate shaft from a 75, 80 cushion joint.. I haven't yet had a chance to dummy up the positioning but from the look of things in Tooheys article it should be fine. I know ray185 used a MWB intermediate shaft for his (to a 60 column).. but I guess I wont know until I get it mocked up.

yep, should work a treat, that's the way i did mine. don't forget that if it's too long, you can shorten it by drilling out the plastic bung and "tapping" the shaft with a hammer because they are collapseable columns.

forgot about the Bj 42 dual batteries.

another thing to think about is, are you going to want to push your front diff forward at all? if so, now is the time to do it, as you have free reign as to where to mount the power steering box, but once it's mounted, your limited as to how far to move the front diff forward.

My front diff is already 2.5" forward.. I dont anticipate moving it any further forward.. I will be using same springs but shorter shackles in the near future..

Do you just orientate the steering box above the diff? so the pitman arm is in line with the Tierod?

The only other thing I would like to do is use the ford shock towers.. but I dont have these yet and I guess it wouldn't be too hard to install them later..

shorty_f0rty wrote:

bad_religion_au wrote:

shorty_f0rty wrote:

bad_religion_au wrote:i did mine in a weekend by myself, so you should be fine.

the two "gotcha's" i found were you might have to move your shock mount,

and you need to move your battery to somewhere else.

what intermediate shaft are you running?

Thats good to hear Adam. I have my 2nd battery above that shock mount so I dont mind relocating that as the main battery is on the opposite side.

I was following Toohey's shopping list from the Cruiser Bible ( http://www.outerlimits4x4.com/viewtopic.php?t=46390 ) and got a intermediate shaft from a 75, 80 cushion joint.. I haven't yet had a chance to dummy up the positioning but from the look of things in Tooheys article it should be fine. I know ray185 used a MWB intermediate shaft for his (to a 60 column).. but I guess I wont know until I get it mocked up.

yep, should work a treat, that's the way i did mine. don't forget that if it's too long, you can shorten it by drilling out the plastic bung and "tapping" the shaft with a hammer because they are collapseable columns.

forgot about the Bj 42 dual batteries.

another thing to think about is, are you going to want to push your front diff forward at all? if so, now is the time to do it, as you have free reign as to where to mount the power steering box, but once it's mounted, your limited as to how far to move the front diff forward.

My front diff is already 2.5" forward.. I dont anticipate moving it any further forward.. I will be using same springs but shorter shackles in the near future..

Do you just orientate the steering box above the diff? so the pitman arm is in line with the Tierod?

The only other thing I would like to do is use the ford shock towers.. but I dont have these yet and I guess it wouldn't be too hard to install them later..

not too hard to install them later, although you might have to pull your steering box to get to the top rivets on the standard shock mount if you don't end up pulling them to do the power steering swap.

i just eyeballed mine compared to 60 series (they sit a tad forward of the centre of the hub at rideheight from memory).

the most important thing is to mount it to ensure the pitman arm arc is paralell to the ground, not slightly askew from it.

My intermediate shaft is from a bundy.

mmmm bundy

I just tried to get a new tie rod end kit for the 75# steering arms but discovered there are two different kits .. one for the HJ and the other for the HZJ.. any tips on how to figure out which bits I've got?

shorty_f0rty wrote:I just tried to get a new tie rod end kit for the 75# steering arms but discovered there are two different kits .. one for the HJ and the other for the HZJ.. any tips on how to figure out which bits I've got?

i'd hope HJ,

the HZJ is the bigger knuckle that runs 80 series shiate

bad_religion_au wrote:

shorty_f0rty wrote:I just tried to get a new tie rod end kit for the 75# steering arms but discovered there are two different kits .. one for the HJ and the other for the HZJ.. any tips on how to figure out which bits I've got?

i'd hope HJ,

the HZJ is the bigger knuckle that runs 80 series shiate

thanks.. thats good to know.. interestingly the HJ is more expensive ($197) than the HZJ ($170).

Sory I havent replied earlier Andy, been busy with the house.

Give us a call on the tie rod end set, I sould be able to get them cheaper for you if you want.

My steering box is forward of the stock shock mount but I have a body lift which helps with clearance from the rad support panel. I did have to grind out a bit from the back of the shock mount to clear the intermediate shaft. My intermediate shaft is MWB from the box right the way through into the top of the steering column itself. Pretty sure 75, bundy and MWB are all the same shaft. I did have to shorten it a little. Battery definately has to go. You'll need a 75 or 60 steering dampener (40 is far too short, plus they are skinny pieces of crap anyway) and a bracket for the fixed end. You shouldnt need a press for anything at all. Dont forget to use plenty of anti-seize on the tie rod end threads.

Ray

Hey Ray,

no stress mate.. I know you have more important things to worry about lately!

Thanks for reminding me about the dampener.. THat bit had slipped my mind!!

If you can do a better price that would help out a bit.. did you say you got your dampener bracket off of a 75?

Yeah, I used a 75 bracket as it came with the dampener and tie rod/drag link from the wreckers.

RAY185 wrote:Yeah, I used a 75 bracket as it came with the dampener and tie rod/drag link from the wreckers.

found that image thanks ray..

You know its coming on 2 years since I did this conversion and I still havent changed the bolts on that bracket.

I was reading up on Twisty's thread on 3rdrock4x4 and Rogues has provided LOTS OF THINGS TO CONSIDER and take into consideration when doing this..

for example.. the angle on the steering unis, the angles of the TRE's, etc, etc.

this will help heaps!

I'll have a look into some towers for you Andrew, i think Cracka still has 1 pair lying around, but if not he was talking about getting some sent over again. It would be worth doing it all at the same time if you've got the $$.

Looks like you've got most of it sorted.....onyl thing I hate about my setup is the 75 series column, would have modified the stock one or used a 55 series one if I did it again.

TWISTY wrote:I'll have a look into some towers for you Andrew, i think Cracka still has 1 pair lying around, but if not he was talking about getting some sent over again. It would be worth doing it all at the same time if you've got the $$.

Looks like you've got most of it sorted.....onyl thing I hate about my setup is the 75 series column, would have modified the stock one or used a 55 series one if I did it again.

Hey Dave,

Still very interested in those shock towers.. if you've got them i'll take em!!!

I reckon i'll take the shock tower off to mod it so when it does come time to do the f250 towers its a little easier.

I was lucky enough to get a 55 column up all the way from Adelaide when Bad_religion_au came to visit.. very lucky and very appreciative!

You can move the shock tower back and cut less of a nothc out of it, its a bugger to bolt back on though, do-able, but a bit of a bugger

hmm.. if i can get my hands on the f250 towers on monday it might leave them off until then.. all depends if twisty's still got them available..

yeah dont panic if you cant, its a common mod in USA but in AUs they are rarer, so i never bothered...

Why you wanna change towers? clearance?

bj on roids wrote:yeah dont panic if you cant, its a common mod in USA but in AUs they are rarer, so i never bothered...

Why you wanna change towers? clearance?

longer shocks ... bilstien 5150s!!

Got some towers for you Andrew.....will send you a PM.

cooool

shorty_f0rty wrote:If you can do a better price that would help out a bit..

Mr S Forty, you're barbecue is ready.

RAY185 wrote:

shorty_f0rty wrote:If you can do a better price that would help out a bit..

Mr S Forty, you're barbecue is ready.

wonder if i get a free reacharound with that?

shorty_f0rty wrote:

RAY185 wrote:

shorty_f0rty wrote:If you can do a better price that would help out a bit..

Mr S Forty, you're barbecue is ready.

wonder if i get a free reacharound with that?

haha, yeah no problems, just ring the hotline again and someone will organise that for you.

got my bits prepped ready to go..



last remaining bits for the shopping list are:
TRE kit
60 or 75 steering dampener
75 dampener chassis bracket
high pressure power steer line between box and pump

think thats it..

Andy, what brand steering dampener do you want? I can get you Monroe or Maxitrac unless you were thinking something else.

These guys are good for high pressure hoses, they'll come to you and make one to suit.

http://www.mobileautohoses.com.au/

Ring them for a price.