Outer Limits 4x4 Board

Last weekend Bluey74 & I attempted to fit the running gear & suspension from a HZJ 75 into a HJ 75 chassis & body.

To do this swap, we changed everything, the only thing that was left original in the HJ 75 was the body/doors/guards/roof etc, the seats & the pedals. We swapped everything else. Including dash, heater, fan & air con units.

The following is a list of things different that prevents a direct swap between the models:

1. The retaining plate on the end of the front suspension pin is different. The hole is in a different location will not bolt up.

2. Engine mounts. They are completely different between the 1HZ and 2H motors. gearbox mounts are exactly the same on the chassis.

3. Instrument cluster. The Mounting tabs on the instrument clusters are different between the 2 models.

4. Inputs shaft on the H55 gearbox. They are different between the 1HZ & the 2H. The 2H uses a coarse spline & the 1HZ uses a fine spline. Therefore the clutch plates are different between the models.

5. The vacum canister is in a different location. The HZJ is on the drivers side under the master cylinder & the HJ is on the passengers side.

6. The power steering boxes are different. The HZJ is slightly longer & smaller than the HJ in the barrel from the steering shaft. The steering box will still bolt up betwwen models, as it can be taken up in the slip joint. However the power steering lines need to be carefully bent so they fit. The Steering arm is exactly the same.

7. The electrical system is almost identical except for the plugs. They are completely different & therefore the entire electrical loom has to be swapped or butchered. This includes having to swap brake light switches.

8. The fuel senders etc on the fuel tanks are different and in different locations. They will not swap over.

9. The fuel & brake lines are different, but are a bolt in.

10. The bracket on the passengers side chassis rail which picks up the union between the flexable line & steel line in the hydraulic clutch has no threaded hole to bolt into.

11. Brake master cylinder is different. This is because the HJ uses rear drum brakes & the HZJ uses rear disc brakes. The load proportioning valve was also swapped.

DON'T TRY & DO THIS SWAP IN 2 DAYS Even with 2 people this swap would take 3-4 days to completely do.

Bluey74 & I will add to this list as others things come to mind.

I think you meen a HZJ75 into a HJ75 is this correct?

RUFF wrote:I think you mean a HZJ75 into a HJ75 is this correct?

Yes I do. The difference between a HZJ cruiser & a HZ holden would be pages long

I get asked about this conversion all the time at work. You will also have to run a return fuel line back to the fuel tank both if you have them. This is a big conversion that looks simple I have heard blokes spending upwards of $10 000. I only have 1 answer It is easier to just go and buy a HZJ 75.
1. The retaining plate on the end of the front suspension pin is different. The hole is in a different location will not bolt up.
Where exactly is this as they share all the same suspension parts.

skootin wrote:I get asked about this conversion all the time at work. You will also have to run a return fuel line back to the fuel tank both if you have them. This is a big conversion that looks simple I have heard blokes spending upwards of $10 000. I only have 1 answer It is easier to just go and buy a HZJ 75.
1. The retaining plate on the end of the front suspension pin is different. The hole is in a different location will not bolt up.
Where exactly is this as they share all the same suspension parts.

You are 100% correct about the fuel lines. We were lucky as we had a rolled wreck to pull all the bits & pieces off including the fuel lines.

As for the front suspension pin (sorry I haven't used the correct terms) The pin that goes through the fixed end of the front leaf spring is the one I am refering to. IE the opposite end of the spring shackle. The teardrop shaped retainer plate is slightly different shape between the 2 models & the small bolt that holds the retaining plate on will not go in.

Hope this makes sense.

We were lucky as Bluey74 picked up a wrecked HZJ75 for $3500 & it was driveable .... just. So $3500 for the wreck + $500 for new clutch & pressure plate & flywheel + $1100 for overhaulled fuel pump & injectors + $500 in other parts (oils, gaskets, timing belt etc) so it cost about $6000 all up. You are right it may have been cheaper to just go & buy a HZJ75, but it is no where near as fun

Let me add a couple more items

12. The front driveshaft from the HJ75 will not bolt up to the HZJ transfer front output.
13. The HZJ instrument cluster has different electrical plugs from the HJ75 cluster. Unless the entire HZJ harness is used, there is a lot of wire splicing and soldering.
14. The HJ75 tacho will not work with the 1HZ motor. An HZJ tacho is needed, but it will bolt into the HJ cluster. The fuel/temp gauge will not bolt into the HJ cluster as the bolt pattern is different. Although the HZJ gauges are back lit (the instrument faces are transparent) whereas the HJ gauges are not, the difference is minimal. Unless you point it out to your mates, they'll never notice it, LOL.

Mytqik, did you swap the wiring harness over? I just had a 1HDT installed into my HJ75 also. There was a lot of wiring loom modifications to be done as we did not have an HZJ75 wiring loom. Questions for you:

i. Did you run a low fuel warning lamp wire from the fuel tank? I kept my old HJ75 instrument cluster, but I swapped most of the guts from the HZJ75 cluster into mine. I want to use the HZJ75 cluster too, but it is too much work.
ii. Do you have AC in yours? I had to have new lines made with HZJ fittings on one side and HJ ends on the other. I kept the HJ condenser and receiver.

Cheers,
Dave

Yeah we did change the entire electrical loom, from front headlights to rear tail lights. Massive job as it requires the complete removal of the dash etc.

Another one is that the electrical plugs on the steering column it self are the same, so we did end up using the original.

As for the air con, we used the HZJ unit & it bolted into the HJ cabin OK.

Also the steel dash on a HZJ is slight smaller at the door pillars. If you look under the dash at the door pillars, there is a tag from the pillar which bolts onto the steel dash. On a HZJ they are slightly higher up so a HZJ will fit into a HJ but not the other way around. We needed spacers (about 12mm) to fill the gap & longer bolts.