PDI Slimline Core for VDJ200 Series - Works with Winches.

The PDI Front Mount for the 200 series really allows it to maintain the cold day driving performance. The result is more spirited and allows the figures from the dyno sheet to be available all the time.

It comes more into its own when loaded up, towing, playing around or on the beach where the ECU otherwise must pull fuel out to maintain safe operating parameters.

While fitting time is an aversion for many workshops who prefer to push a ECU reflash and install a set of fans for max return, the problem has been for those who are running a slimmer tucked up bullbar and winch install. Our previous design had major interference issues with the winch so it was one or the other -

NOW you can have winch install with the benefits of a PDI Front mounted intercooler. Also available with the heavy duty transmission cooler upgrade.

CLICK HERE FOR MORE INFO

We're calling it the 305 - a 300 series V6 in a 105 (with the 6R80 F150 auto).

At the moment I personally own five Landcruiser 105 (plus some other models) and its been more in the past.  

I like that the 105 represent the last and best of Toyota true offroad family wagon development, starting with the 45 series wagon. While I realise the IFS models are very capable offroad I see design things that indicate they are more of a street tourer and that the more rugged 70 series continues to be a rigid front beam axle.  Lots of the design in diffs, transfer case and gearbox was kept from 1998 through to the current model.

I've built and owned a number of 1HDFTE converted 105 and have thoroughly enjoyed driving them, making each one better than the one before in comfort, drivability and durability.  With PDI allowing me to develop products and support customers dreams, this has been a great combination.

2 years ago I sold my FZJ105 with modified 1HDFTE manual with factory lockers.  For over a year, it was happily punching out 302kw (430hp) and 1070nm at the wheels and it was fun under all conditions. It was used for family holidays, going out beyond the back of Marble Bar and places that only trusted and reliable vehicles should go. Since I felt the manual transmission was at the limit of its ability we started investigating a stronger auto option and decided upon the 6R80 from Ford.

Initially we dropped a modified 1HDFTE in front of the standard A442F and stayed together for the 6 months until we had the adapters and systems in place to fit the 6 speed auto.  From day 1 this has been faultless and the conversion has transformed the cruiser in a way that I would only want to drive an auto for the Landcruiser.  With (a disappointing) 285kW at the wheels it is fast and gets me around easily.  Off-roading is more fun than ever as I had to try test and potentially destroy the box "for research and development purposes".

In late 2022 a conversation planted a seed and over the Christmas break, it took root.  In January we got our hands on a 2021Toyota 300 series crate motor.  This is the F33AFTV, which is a V6 diesel 3.3L which looks like a 1VD V8 in many ways but is simpler and improved.  The engine is a 90deg V configuration with turbo and exhaust ports located inside the V and intake ports on the outside. After many clearancing issues were considered, it was time to start fabricating the custom parts and working until we saw a “blocker” that meant it couldn’t happen.

When Motec said they thought the new unit could be run using their ECU, then it was game on.  

Looking at the modern vehicle engine bays can be rather daunting for the unfamiliar and sometimes very troublesome if you have to repair them.  The aim is to have the best of Toyota mechanical tech but without the compexity and baggage of owning these modern vehicles once outside of warranty.  When you consider a common rail engine, effectively we just need to control rail pressure and each injector plus vane control for the turbo - these have been very reliable.  We do need a few inputs - accelerator pedal, boost pressure, rail pressure, crank angle sensor, camshaft angle sensor a simple setup, but again these are simple and can be easily replaced if they give trouble. Based on the 105 being produced in 2000, we shouldn’t need to worry about EGR, EGR cooler systems, DPF and everything that supports those parts

The engine sump was modified and the engine mounts made.  The long list of required parts and aftermarket bits had been started and within a month it was sitting on mounts with a plan to get it connected to the 6R80 transmission.  Delays in design and being busy with supplying PDI product and other kit development resulted in the project progress grinding ahead slowly.  Eventually we had a gearbox adapter to the engine and with the transfer adapter in place we could finalise some more details. Reversing the walk behind forklift over my foot late June further put pressure to focus on other things.

Custom exhaust manifold was required and we had planned to run a Gturbo VNT single turbo from the VDJ79.  While it won’t be as responsive as having small turbo sequential twin system like the 300 series has from the factory, we wanted simplicity in both installation and control.  We are still hoping to max out somewhere between 360 and 400hp, while building strong power from 1650rpm. We know the std injectors can support 400hp.

The plastic intake manifolds would be replaced with custom alloy units.  These are to allow forward facing intakes for connection to a front mounted intercooler.  Joining them together still needs to be considered and done.

For extra strength and GVM capability we got a DWIZ front diff housing (rated 300kg above the factory unit) and got the Packard Automotive front brake upgrade kit.  Custom radius arms from Boosted Diesel Services were required to roll the diff back and give clearance to the engine.  Also, direct fit hydraulic bump stops from Slinky Customs were added to the build list, since the front diff was going to be able to push on the starter motor mount with enough compression.

The aim was to be ready for the Perth 4WD show so a few weeks back we planned to get the project back on track.  The chassis was sitting there with the engine, and while that needed lots of work, the body had also been waiting for a while.  Things had been borrowed for testing or used elsewhere and other things had been partially installed. There were upgrades in the cabin that were needed to be done to make it the next step forward in development.  The climate control system facia can be updated with the GXV spec that has auto functions for temp control and fan speed.  This is a nice mod, once you get used to it.  Seats were swapped out for the 50th anniversary seats, which have higher quality material and additional adjustments on the drivers seat, plus the drivers seat gets denser and thicker foam to become more of sports bucket, while still being original fitment.

We have things in development and production for the rear diff and transfer case so in the interim, standard parts were used.  We like the full time transfer case with mechanical LSD, since with so much power, its important to be able to get power to the ground for the daily commute.

We have been using Manta exhaust systems on conversions for some time and were able to get the rear part fitted and just needed a custom dump pipe.  A quick phone call to the Manta boss and then some estimations on what was required, resulted in a section bent up with three bends and this was basically a direct fit onto the 180deg bend from the turbo.

Lets hope November doesn’t get here before its running…...


PDI 100 series kit information

At PDI we ensure our products are optimally designed for max efficiency.  This means big core options and suitably sized and configured piping kits.  Our 100 series intercoolers are the largest we can fit in the front of the 100/105 between the headlights – while some might argue that a larger cooler can be placed out the front, we have seen significant benefits for the cooler being close to the condenser for max draw through from the main engine fan.  Placing a core further away requires the need to consider the addition of cooling fans, since there will be no draw from behind and typically a bullbar is placed.   In addition to designing the pipes so they can use less joiners and simple silicon, that can be easily sourced we have chosen to use 2.5” piping to improve flow characteristics.

We incorporate a fitting in the base of the drivers side end tank, being the lowest point in the system, for draining of any oil that may potentially build up.

If you have a late model 100 series, you may note that Toyota have added a small black “vacuum hose” from behind the intake which disappears into the insulation around the intercooler piping.  The purpose for this hose is to push any oil in the lowest part of the plumbing, back into the intake and prevent it to build up – this works due to the pressure differential to the other side of the butterfly. With a PDI intercooler installation, we typically just block this hose, but it can be connected to the port at the bottom of the intercooler with an extended hose and barbed fitting.

To cater for different airbox and turbo setups PDI have 5 different hot side pipes so we can provide the best fitment to your install – we will exchange these at $100 (plus any silicon or clamps you may need) for those who are going to be doing upgrades later.  Also available is the crossover delete to clean up the top of the engine.  That adapter itself is the best designed for the FTE and provides mounting for the MAP sensor and sensor filter.

If you have an auto we provide the largest transmission cooler we can fit there and place it our front so that the transmission gets optimal cooling.

We had a customer come in recently to resolve ongoing issues with hoses blowing off (for a competitors kit).  A few things we noted were:

  1. They had been running smaller pipes for hot and cold side – this is OK for std turbo configurations.

  2. PDI have one pipe on hot side and 2 on the cold side (to allow for engine movement and make shipping easier).  The other kit had 2 pipes on hot side and 3 on the cold side.  This means 7 joiners, instead of 5.

  3. PDI use much higher quality (high torque, liner style) clamps in all our kits.

  4. The joiners were too short and clamps were incorrectly placed to ensure trouble free motoring.

  5. The oil suction pipe, as described above conveniently went into the closest point in the hot side piping.  Just in case you missed the purpose of this hose, it should be going to the lowest point in the intercooler system.

 If you are interested in more information or purchasing click the link HERE

 

 

 

Next Generation Ford Ranger is in the shop for Intercooler Upgrade and Transmission Cooler

We have started the design for an Next Generation Ford Ranger upgraded intercooler and transmission cooler. While the space at the front looks huge there are some challenges and we are excited with the design so far.

This will be the largest transmission cooler you will see fitted to the any Ford Ranger. In fact we have been running the Ford Ranger 6 speed auto with 280kW at the wheels and this large cooler since March 2022 and have only briefly seen it get just over 80degC when giving it a hiding. We are well pleased to be able to offer it in the Next Gen Ranger.

Expect the transmission cooler kits to be available April 2023. Intercooler kits are expected around mid year so looking forward to releasing them as well.

PDI Transmission cooler for Isuzu NPS and NPR AMT

We got the call mid 2022 from a company reporting major overheating issues with the auto in the NPS AMT. Customers having to pull over and “wait an hour” or water hissing when used to cool the transmission down.

The company knew we were about to throw the cat amongst the pigeons with our new range of transmission coolers so asked if we could have a look at these.

After various checks we decided to mount the core up in front of the intercooler and so vehicle motion and the main engine fan can pull the air through. This means no thermo fan will be required.

The core itself is rated to 45,000BTU and is suitable for industrial application. The bracket is a single piece unit, made from mild steel and then zinc plated and coated in black for longevity. The clever bracket design makes this one of the easiest items to fit to your truck and we are sure it will outperform any other item that may get released.

If you are looking for the best transmission for you Isuzu truck or a range of 4WD vehicles check out our pages. CLICK HERE

Short Shifter Upgrade Released - Critical Part Replacement Offered to all Sold kits.

We constantly strive to bring the best products to the market and try to innovate where we see a need or development potential.

 

Regarding the PDI short shifter, we are very pleased with the result with function, but have realised one area of the design that could be improved.  The shifter works by raising the upper pivot (fulcrum) point to change the throw of the shifter significantly.  This required a reducing in the ball diameter and we were able to change from the H150 gearbox box bushing to the smaller R151 bushing, which itself gave design challenges and a thinner wall thickness over the upper section of the inner sleeve.  The pins located in the side of the upper section are designed to stop the stick from rotating so the greater the bend in the stick (and aggressiveness of the shifts), the more side load is placed on the pins. For a few customers a pin as sheared off and has resulted in a sloppy stick and for a couple people the pins have made it past the bushing into the gearbox.

 

NOTE: When removing the sticker where you may suspect the pins to be broken, we suggest keeping the stick in place while rotating and lifting the outer sleeve to disengage.  Either remove the pins before lifting the stick off the bushing or remove the inner sleeve together with the stick itself.

 

The thought of metal parts freely moving in the gearbox sounds really bad, but there are many, many stories of dropped bolts and broken teeth in the bottom of the manual gearbox which have resulted in no further damage over many thousands of km driven. That said, if you do drop something into the gearbox, using magnets and other tools to try remove is advised.

 

The upgraded inner sleeve is made of stronger steel and we have been able to more than double the wall thickness in the area supporting the pins, which means we are no longer relying on the quality of the weld (only) to keep the pins in place.  Additionally we have been able to tighten some of the tolerances to make the stick feel more solid. This is a recommended upgrade for all those running our short shifter so please make contact with us to request the replacement part.  Equally if you have sold the vehicle or installed it for a customer then please assist us in making contact with the relevant owner.

 

This replacement part is offered free to those who have a PDI short shifter purchased before June 2022 and will be sent out in the mail upon confirmation and request.

A442F upgrades

Im actually a fan of the A442 and transmission rebuilding companies either say they are great or a clunky old box and don’t want to touch them (if you’ve increased the power). Many years ago their were stories of Viper engines being run in front of these with great success. Lockup kits were all the rage, but as torque levels increased, companies started getting scared about them slipping since the contact area on a standard torque converter isn’t that great.

Lots of companies offer upgrades to the A442F, and behind the FTE these can result in a very clunky low load 1-2 or 2-3 gear change and can only be nice when pushing them a bit harder. Lots have issues with slipping clutches and therefore off to a rebuild.

What do we know.

We were happy to do some testing on our cable line pressure operated A442F (previously behind a petrol and then behind an upgraded FTE. We didn’t actually have any work done to the valve body so shift changes were slow and at full power it would slip on the changes, but could hold when in gear. We did learn enough to know what makes a difference and is a worthwhile upgrade.

Except for the very first of the 1990 80 series Landcruiser A442F (which was fully hydraulic) the gear changes are controlled by an ECU when in D. The cable was used only for controlling internal line pressure.

The A442F behind the 1HDFTE and 2UZ, has an extra solenoid inside the gearbox specific for controlling line pressure and have no cable. This is because these engines have a fly by wire throttle, and I wouldn’t consider this to be an “upgrade” to the transmission, but rather a compromise as its application isn’t clever or have a great range.

Line pressure in the FTE and 2UZ can be increased for high load situations by putting a switch in the wire from the controller to the transmission. Effectively if the wire is cut you get max line pressure. This is because the spring that holds the pin down in the solenoid isn’t great and weakens with time so that for a set hold signal it will sit further off its seat and line pressure continues to drip with time. Also a modified valve body doesn’t seem to increase the rate at which the pressures ramp up but rather raise the whole pressures so you get that harsh low load gear change and nothing particularly impressive for line pressure.

SO…..What to do???

Based on what we have seen so far I would plan to install a valve body from a model with the cable controlled line pressure and use this in conjunction with a new boost controlled pressure device (soon to be released PDI LPC). Additionally we should organise the valve body upgrade (or do an exchange) since we have another fancy trick to get much more line pressure when under load.

The gear changes will continue to be done by the factory or an aftermarket controller, we just have our own control for line pressure and we have this based on boost pressure since on a turbo vehicle the torque comes from boost. This new system will give max line pressure above 20psi and 60-80psi when not making boost. This results in

  1. the gearbox having very good strength when pushing it hard and being able to hold regardless of pedal position or how the tune and boost responsiveness is setup

  2. at low load the shifts will be silky smooth as the line pressure is lower.

  3. people doing FTE conversions into an auto 80 or 105 can keep the transmission, and these mods done while have line pressure controlled relative to boost.

Next Step.

If you are interested, please contact us via email to see if exchange valve bodies are available and then standby until the LPC product is released. We suggest not getting any valve body mods done until you see what we can do. If you don’t have a cable operated line pressure valve body then start hunting for one.

Is that the best we can do?

If you are pushing the A442F hard and considering a rebuild, I would install the Wholesale Automatic Billet torque converter and think about the extra clutch plate in the back end. Find a local place to do the main part (clutches etc) build, but due to complexity of automatic transmissions I don’t have a problem having experts in their field do each part. Quite a number of transmission shops know very little about torque converters and get them done by a specialist. Equally lots will offer to do your valve body, but we’ve been in lots of complete builds that aren’t ideal due to valve body setup.

NO - the 6R80 conversion is the best result for getting a strong smooth changing transmission behind your 6 cylinder and we expect to have these as a kit some time in 2022.

Update on the 6 speed auto in the 105

First thing to say is that it is very, very nice. It’s hard to say its the best mod yet, as we’ve done a series of engine and vehicle mods to get to this point, but its certainly up there and besides the power (286kw at wheels) its the most defining feature of the vehicle when driving. Anyone who has been taken for a drive has been super impressed and keen to know more.

As we know it can handle some serious power, we expect this will allow people to have a superior shifting transmission and pursue the power limits without budgeting to regularly blow gearboxes.

Whats good about it?

  1. We can have 4 different maps for shifting and normally just use the one - these can be modified within the laptop software to tweak in line with engine output characteristics.

  2. For “normal” driving is changes are barely detectable and as more pedal is added the line pressure is raised so shifts become more defined and shift point RPM is increased to stay within the ideal rpm range for max acceleration.

  3. Has full tiptronic shifter installed to make it hold the gear or to take full control of shifting or keep the revs up for getting ready to come out of the turn. Its ideal if wanting to make it labour in a gear, rather than change down. The shift response is almost instant.

  4. The shift timing for clutch engagement is all self learning using base start maps so as things change it can be told to reset from the control box.

  5. Coupled with the 3.9 ratio diff gears it will cruise at 1760rpm at 100kph and 1935rpm at 110kph

  6. With our large transcooler, on a 20km beach run we didn’t see much over 70 deg on transmission temp.

  7. A standard box can handle 1000hp and maybe over 900nm in standard form. Ours is upgraded with stage2 clutch packs and replacement internals to take power capability up to 1200-1400hp.

Whats bad?

  1. We are working on new adapters and torque converter design for the F150 box so this has delayed release of kits and being about to finalise the pricing. The initial release will have 10 kits and are taking expressions of interest already.

  2. This is a full electronic box and requires solenoids and control box to function - no hydraulic mode although can limp home in a low gear.

  3. Currently one of the required inputs is accelerator position so cruiser control is not available unless you are using a cable system (like the FZJ105) which works in my FTE converted 105. We hope to find a signal we can get from ECU to simulate pedal movement, but that hasn’t been investigated yet.

Whats next?

  1. Finishing developing a kit for the 1HDFTE engines and offer the box in standard or upgraded form. Similarly for the torque converter will be triple plate or single for lockup.

  2. Do the same for the 1VD engines in the 79 series for those wanting to have a 6 speed auto but choke on the idea of buying a kit for $25,000.

  3. 1FZ setup for the turbo guys who want to run 600hp but can’t find a gearbox to hold together.

If you are interested please send an email (info@pdicoolers.com.au) and we will make the information available for others. Im keen on getting this out there so others can experience this but need to reduce the time on the phone talking about it. If you want to go on the list to be emailed once we are ready to go and have pricing sorted please specify in your email.