How is your project going? I would like to see some new pics if you have time. You have redefined the term, project!

 

I'm sorry to report that I haven't worked on my truck at all since I started a new job as a CNC machinist. I have no idea how I'm going to finish this project working 60 hours per week (with the commute). I spend most of my weekend doing errands that are delayed from the prior weekdays.

Maybe at some point I can reduce my hours and get back on this. I'll definitely update when I start on the truck again.

Roy

 

sounds fair enough. robert

 

I feel your pain Roy, but just think of all the cool stuff you can CNC for your rig at work [if they let you]. Don't work too hard... Aviator

 

Until you get back to the "real" job,I'll be waiting here patiently!

 

Hi folks,

It looks like I'll be working lots of over-time for some time. If anyone is interested in purchasing this truck, please PM or email me. Everything but the winch will go with the truck. This includes the new tires and Mercedes turbo-diesel engine and auto-trans. I just won't have time to finish this project.

The truck is in Frederick, Maryland. All reasonable offers will be considered.

Thanks,

Roy

 

damn thats too bad buddy I was just thinking about you yesterday I was going to ask for an update on the project...
at least more work is better than less work...

 

Well, my wife has asked me to NOT sell the truck. She suggested I take a break and fix up my Subaru, since that should only take about three or four weekends to finish. So, I guess I'm not selling after all.

Roy

 

Good for you...

 

yay for your wife saying no to selling it
that truck is going to be too cool when it is finished you would slap your self for getting rid of it later on.

 

rv status!

 

Yea..ide like to see an update! cool project

 

Well, there's been a change of plans. Every time I walked into the garage, I was overwhelmed by the amount of work remaining on the truck. And, after working as a machinist for seven months, I was, honestly, unhappy with how the camper body was turning out. (even after gutting it twice and starting over)

So, I walked out with my grinder and a cut-ff wheel and removed all of the "new" body and took it to the dump. I decided to make a four-seater, diesel Hi-Lux.

Luckily, no one ever took my original top from work, so I brought that back home. Here is the planned truck:

 

I modified the fiberglass top so it would have an "upright" cab appearance. I never liked the slanted 4Runner top when shortened. I then closed the back of the cab with fiberglass, and created a step that fits a Ranger rear glass I found at the scrap yard.

Then, I added 1.5" tube around the top of the "new" bed to stiffen it up a lot. I followed that with boxing in the new bed with sheetmetal and many reinforcements. Two "barn-door" tailgates were fabbed from 1.5" tube with two full-length piano hinges were used to mount them. I used one spring-loaded hitch pin on each side to secure the gates when closed. Stake pockets were added to the top of the bed for future use. If I can't go long-bed, at least I can go HIGH-bed.



Boxed in the bed

 

Donor engine with original Merc auto trans.

It's an OM617 Mercedes turbo diesel.

 

For now, I'm keeping the IFS. This swap will not include a body or suspension lift.

The original plan was to use the Benz automatic and the OTT divorce transfer case adapter.

After mocking up the engine trans combo, it became clear that without a SAS and suspension-lift, putting a front driveshaft on would be impossible. The Benz trans is too wide for too long. The driveshaft would never clear the housing and trans pan.

I had the engine/auto-trans combo in the engine bay, and it's a tight fit, but, I think with the manual-trans, it's do-able.

Mating the Toyota W56 to the Benz engine looks like it's going to be a little involved. (This is my first engine swap by the way) I know this can be done because I have some limited photos from a guy who did it. He was a machinist, and he couldn't remember all the details of what parts he used, and the photos I do have show little detail. These were second-hand pics and info. I found the thread on ToyotaDieselMadness.com of someone who planned to replicate the swap, but later, he decided to keep the Benz auto-trans and leave the truck 2WD.

 

Removed the Benz transmission today, and mainly sat and familiarized myself with the engine layout, plumbing, etc.

This is an all-mechanical diesel. No electronics of any kind. This engine in stock form, is rated at 125HP and 175 lbs of torque. I've been reading up on the Benz forums, and with a few simple mods, can produce about 170HP and 240 lbs. of torque. Intercooling this engine is pretty straight forward as well.

The "OM" series engines are known as the most dependable engines Mercedes has ever produced; many going 300,000+ miles before needing a rebuild.

 

Here is the thread that has the pics of the first install with the five-speed.

I don't want to link to all the pics because it might be a bandwidth issue.

Roy

http://toyotadiesel.com/forums/showt...light=mercedes

 

Transmission and torque converter are off. The flexplate has obviously been balanced. Now, the question is, is it balanced to itself or balanced to the five-cylinder.

I have a 240D manual flywheel in route from NC. I'll pull the flexplate and send it and the replacement flywheel to a place near me called "In Balance". I hoped it's just balanced to itself.

There are rumors on the web that the five cylinder is somehow balanced with the trans attached, and if you change the trans, you'll always have a vibration, blah, blah, blah. I think it's all BS. We'll see shortly.

Flexplate with balance holes:


Here's a web-pic of the replacement flywheel, clutch and a Benz trans from a 240D.

 

I have read about this "balance issue" quite a bit while researching this swap. I am going to find out once and for all if this is true. I have a feeling that it's not true. It makes no sense to me to not balance the engine, and instead balance the two units as one. Honestly, I don't even see how that's possible with no access to the flywheel/flex-plate while the units are joined.

Tonight, I pulled the flex-plate and the Benz transmission "transition" plate that goes between the trans and engine block. I threw those in the trunk along with the Toyota manual flywheel. I'm now waiting on delivery of the 240D manual-flywheel I got on eBay. Progress will slow until that arrives.

While I'm waiting, I think I'm probably going to organize the garage and strip the engine down to the long block, clean and paint everything. A wire was between the valve cover and head, and everything is pretty damn filthy.

I'll post updates as they occur.

Roy