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1
What are the specs on the radiator?  I skimmed the text and didn't see it.

It's an AFCO and I think the part number is an 80100n.  I had the inlet and outlet modified for 90 degree bends and aluminum angle iron welded to the side for mounting.  Out of the box the radiator is about $150.00.   

2
Hi guys,

What thickness sheet steel are you all using?

After some reading I decided to go with 5mm thick sheet, with the mount being  a "three sided box". I thought this would be plenty strong enough but a good friend of mine says that every truck he ahs seen with 5mm thick mounts has failed... I'll get some pics later)

Surely 5mm is enough isn't it? the chassis side of the mount is only about 2mm thick!

Thanks.

I used both 3/16" and 1/4" on my mounts (4.7-6.3 mm)  never had a problem.

4
Are there any updates on this build.  I'm curious to see how it turned out.

Been wheeling it for a year and a half now.    Love it.  Only issues were the power steering pump is not strong enough for 37" tires, and I had a couple of Jegs thermo switches for the cooling fan go bad.  









SHORT VIDEO AT fLATNASTY OFF ROAD PARK. --->    http://www.youtube.com/watch?v=4tdFo2q9ZEg&context=C40f63dbADvjVQa1PpcFNk_JINBkRjKg5I8tZBOIWbYQHkRwJGdh8=

5
That would be my truck.   Thanks..    No problems with the motor mounts so far.       The urethane mounts I used were actually made for a Mazda RX-7 Turbo.  The stock Lexus ones would have worked too but so far every Lexus I parted out had broken motor mounts and since I couldn't find anything aftermarket made for the Lexus I had to do something different.   

As I mentioned in the build thread this design allows you to adjust the motor height as needed. 

6
You will basically have to remove any OBDII emission stuff from your truck and use all of the OBDI stuff from the Lexus.    There  is no way to make the Lexus motor OBDII compliant because the computer and all measuring electronics are completely different.  You would have to get a donor from a 1996-1999 SC400 to be OBDII compliant.  If you don't test for emissions then you should be fine.  However, it may make it tough to sell if you ever decide to. 

As far as the tranny, I'm not sure about the electronic's issues but I know they are different.   I just used the lexus tranny with my swap but your situation is a little different since you need a left side drop transfer case.   If it was mine I would install the output shaft and 4wd adapter from the 4Runner transmission into the lexus tranny.  This will however require you to disassemble the transmissions - messy job.

7
The tranny should hold up as they are virtually the same.  The one thing you may have a problem with is that you have an OBDII emissions vehicle that you want to put an OBDI motor into.   Emissions standards changed in 1996 from OBDI to OBDII.   I don't know what the emissions laws are in your state but you may want to check that out before doing it.  Some sates also do not allow the installation of an engine older than the vehicle it is going in. 

8
Ran the 2 rear O/2 sensors through the floor.


I made a battery tray for the drivers side.    I made it so I can use the factory clamp.



I had a local guy do my wiring.  He did an excellent job and I am extremely happy with the quality of the work. 
 
I have to put everything back together and tidy up some of the wires but the biggest part is done. 

here is a short video   

http://www.youtube.com/watch?v=whvJbEh5q8o

9
It gets a bit messy with all the hoses.  I wanted to make sure none of them rub each other.  I don't want any stupid failures on the trail






Also did some more re-assembly tonight. 







The fan comes really close to the front of the engine.  This is why careful planning is necessary if you want a puller fan. 



I got a whole upper intake from a JDM Toyota Soarer (Its what the Lexus SC400 is called in Japan).  I bought it mainly for the factory EGR bypass stuff the the Japanese engine doesn't use.   It also had a Toyota emblem instead of the Lexus one.   

Not quite sure which emblem I should use. 

10
Cooling issues are what seems to be the biggest challenge with this swap.  Many of them I noticed that they tried to use the factory radiators, which are much smaller than the factory Lexus one.  I could have had a custom aluminum one built but they get really expensive when you have them custom built.  I  Ended up getting an Afco 2 core unit from my local race car parts shop on sale for $125.00.   I forget the dimensions but I made sure it fit between the framerailsand wasn't too tall.  I'll try to get the dimensions and post them later.

My goal was to make it fit with enough room to fit and electric cooling fan set up as a puller.  Even with the engine mounted as far back as possible you only have about 5" from the front of the engine to core support.  To fit my radiator I had to cut a section out of the original front crossmember.  I had a new plasma cutter I wanted to play with anyway.   I sectioned it out and put in some 1/4" thick angle iron.  I still have the square tube from the SAS welded below it so it should be as strong as it was before. 





It fits.


11
Finished exhaust pipe.  I got the rest made with single slip over 3" pipe that I have clamped together just not welded yet.



Got a set of these brand new Borla's XR-1's really cheap on Ebay.  I hated to use these normally expensive mufflers on a trail truck but....oh well.



Relocated the Lexus computer up higher than the stock truck unit.



Here is how I routed the fuel lines.  The Lexus feed comes from the drivers side of the engine so I had to get it from the passenger side of the truck over to the feed line.  I ended up using a combination of 4cyl and v6 factory feed lines to come up with the correct length.   My truck was a 4cyl, which places the fuel filter at the engine.  The v6 places the filter along the framerail so the fuel lines are completely different.   I just re-bent factory Toyota stuff that I bought new.



12
For the exhaust I decided to run dual 2.5" into a single 3".  I wanted to run true duals all the way out but the fuel tank location would have made me have to run them both down the drivers side and I saw no reason to do that.   









13
I'm going to use the shifter out of a 2000 4Runner because it doesn't have the 4wd shifter built into it like the 90-95.  I couldn't use it anyway.  The SC400 shifter hit the dash so I couldn't use it either.  It ended up fitting almost perfect.  I didn't have to cut any metal.   I welded some nuts to the underside of the floorboard to make it easier to install and remove necessary. 




I ended up using a Budbuilt crossmember and modified it to work.   If I had it to do over again I would have probably used Front Ranges.  Its a different design and would have been less work but I already had the Budbuilt.  The mounting location is about 5 inches behind the factory location.   I added a piec of metal each side of the crossmember to utilize the factory bolt holes on the frame.  I also made some mounting points to use the slots cut out on the crossmember.






14
Here is what's going in.   Dual 23 spline turbo transfer cases   :banger:




Here is the motor installed.  I removed the core support so I could install it all assembled.  I had already done it once before when I converted to the 4Runner core support so it was a no brainer.   It did suck cutting the welds that I made after putting it back together.  This time I got another doner support and made it bolt on instead of welding it. 



The drivetrain is long with the dual cases.  I had to cut out some of the floor and the horsecollar. 



15
Many of these swaps use either the W56 transmission or the R151 (there are bellhousing adapters for both) but I decided to keep the automatic.   Inchworm makes their Pre-Runner adapter to convert a 2wd Tacoma to 4WD using a standard Toyota 21/23 spline right side drop transfer case.   Since the Lexus uses the same A340E transmission it will bolt right up. 

Here is the adapter.  Its a 2 piece unit.  Its basically Advanced Adapter's Chevy TH350 to Toyota transfer case adapter and then there is a machined adapter to connect the adapter to a Toyota transmission. 


Transmission with the output cover removed.  The shaft has to be cut near where the splines end.  Unfortunately I was too anxious to get it together so I never got pics of it cut.   The instructions that came with Inchworms adapter are for the Toyota version of the tranny, which uses a different output than the Lexus version so the measurments are not the same.   It was pretty easy to just measure where it needed to be cut though.   Remember, measure three times and cut once, or in my case measure about twenty times. 



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