Toyota + Mopar = Mopota

[VeeJay]

Hey Guys,

I am a New Member here, but I have been reading lot of the Conversions you guys have done, Especially from 289hilux and infotechplus,

So This weekend I took the plunge to complete a convesion That i have never seen done but have only ever heard of it on Forum.

After some Research, I found out that there are two Calipers from Toyota that will bolt directly to the stub axle,

1. FJ40/FJ60 - Apparently have a Two Staged Piston setup with two Different Pairs of Piston Sizing (Two Small, Two Large), will work with standard 3/4" Bore Master Cylinder and Single Diaphram Booster (VG 1970 - CL 1977)

2. HJZ75 - Four Large Pistons, this Upgrade will Require the Use of a 1" Bore Master Cylinder and Dual Diaphram Booster (CL-CM 1980-81)

The Main Issues with the standard Brakes were:
- Pulling to the side depending which Caliper Filled faster and slid accross
- Cost of the Rebuild of them (ex GST $330)
- Calipers being Alloy and Slides being Cast Steel (Expansion Rates were different) and after spirited driving they would lock causing creeking
- Single Piston Items with small pads

Here is a Picture of the Standard Brakes - Ignore the Burn Marks in the Discs :cool:
http://img98.imageshack.us/img98/3073/27022008377pj8tn2.jpg

The Chrysler Stub Axles and Toyota Calipers are almost a direct Fit!, other than some clearance issues, The Dummied up set are FJ60's

http://img91.imageshack.us/img91/8828/24176397fb4if8.jpg

http://img149.imageshack.us/img149/9237/63801610al2dj6.jpg

http://img91.imageshack.us/img91/6145/67141618gs5ao9.jpg

What was Needed to get Calipers working on Discs:
The HJZ75 has 20mm Discs (Please Correct me if wrong), The Valiant has 25mm Discs, So Out came the grinder!

After Grinding 6mm off each side and 3mm up (Real close to the Bolt Shafts) This is what I ended up with
http://img80.imageshack.us/img80/1971/21032008436wl2.jpg

After Grinding, A New Seal Kit was Put through the Calipers as One was Seized, The Pistons Were Actually in Very Good Condition for the age and torture they copped when sitting in a bucket of water for 6months
http://img529.imageshack.us/img529/4497/18032008424ew7.jpg

Then They Were Painted in Satin Black KBS Coatings
http://img89.imageshack.us/img89/6084/18032008426ke0.jpg

After that was done, Since the Bolts went from Metric to Imperial, there were slightly smaller, so I Pressed in Some Copper Piping and Reamed it out bit by Bit with a Drill Press. Sorry No Pictures of that.

Then Came the fun Part! Reassembling the front end....Oh Did I Mention my Previous Mechanic decided to weld in my Upper Ball joint since he couldn't be bothered getting it to seat properly!

http://img245.imageshack.us/img245/2003/21032008431vh6.jpg

Because of this I needed to Purchase another set of Upper Control Arms, So I Did them properly, but i Needed a Press for the Bushes So the Bush Mechanic Inside of me came out to Play!

http://img84.imageshack.us/img84/1339/21032008433fp2.jpg

[VeeJay]

Anyway! Back to the Conversion!

After the Pipe was pressed in, I Decided to Assemble the Stub Axle's with new Discs (CL-CM Discs have Different offsets 54mm compared to the 62mm needed for the conversion) and Wheel Bearings, Then I bolted the Caliper to the Stub Axle and I needed to Double Washer the Caliper Bolts since they Pads are Thinner than the Chrysler Ones and the Bolts Bites into the Disc.

This is the Finished Result!

http://img151.imageshack.us/img151/6043/21032008427qm1.jpg

http://img219.imageshack.us/img219/8465/21032008428ij7.jpg

http://img88.imageshack.us/img88/593/21032008429ob9.jpg

Once the New Upper Control Arm's were Installed and New Ball joints Bolted to the Stub Axle's and New Urethane Strut Bushes the Axles were Installed into the car.

http://img220.imageshack.us/img220/4752/file0006gh0.jpg

http://img84.imageshack.us/img84/3066/file0004so7.jpg
New Booster and Master Cylinder Installed

http://img213.imageshack.us/img213/3319/file0007me1.jpg
The Newly Rebuilt 245 Hemi, Over Bored 040, New High Lift Cam and Larger 265 Head. Engine is Compression Ratio 10.0:1 with .510/.520 Lift

[VeeJay]

The Only thing left on the Conversion is..

Bolt up the New Brake Lines, which are in my mums car but her keys are interstate!
Bleed System
Install Steering Gear (Drag Link, Pitman Arm, Idler Arm, Tierod Tubes)

[VeeJay]

http://img257.imageshack.us/img257/8824/21032008438kv3.jpg

[YOGI8U]

Looking good there Nath, I only wish the Celica conversion for the same brake setup was as simple!

cheers
YOGI8U

[Grega]

veejay. time for some pacemakers :D
great write up.
always dubious about shaving calipers but what you have done seems OK, so long as you haven't contacted the bridge of the caliper with the grinder :)

the BJ with spots i've seen done plenty of times before when the mech can't be bothered getting the interference fit right...

[VeeJay]

my BJ are Screw in, Not Press in.

The trick is to pull it out, thread it in from the botom to clean the threads and it will drop straight in, obviously he didnt do that

[VeeJay]

Brakes are In, Steering is reconnected, Shocks are back in

http://img81.imageshack.us/img81/4707/file0013qj3.jpg

[wa5]

Looking good Nath.... seems like a good conversion.... seeya on Moparmarket :)

[VeeJay]

Finally got the Lines on,
Tried to bleed the system, but its farked, Very Very Shit Pedal Feel.

Yogi has suggested a Vacumme Bleed as they are a PITA todo with Pumping the Pedal or letting them Gravity Bleed

[wa5]

sorry to ask a silly question ... but a mate got caught by this years ago... Are the bleed nipples at the top of the calipers?

Mate bought a VF coupe with "rebuilt front calipers" ... couldnt get a good pedal.. turned out they had been put on the wrong side and were upside down (yes he should have noticed) brake shop saw the problem straight away.

[VeeJay]

bleed nipples are at the top