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Old 10-09-2019, 05:25 PM   #1 (permalink)
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Zuki 2.0 build mod stock

So I built and still building a samurai for mod stock class on east coast and also be something my twin girls (13 years old) can drive while on the trails. My regular trail zuk is tons, 6.0, atlas, 39 stickies so to much power I feel for them to learn.
I started out with a rusted samurai!
Iíll try to post as many in order. I donít usually do builds on forums at all but a lot of people keep asking me to do it so here we go!
Started out 2.0 but blew that up and went 2.3
Auto trans 03-72L. Not LE!!
Dana 300
Toyota axles with low pinion e lockers




What I end up with and still building
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Old 10-09-2019, 05:28 PM   #2 (permalink)
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Interested in the adapter you used to put the Dana 300 in there


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Old 10-09-2019, 05:31 PM   #3 (permalink)
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Cut housing to get springs under but not hang down a mile. Also moved them in a 1/2Ē more than stock Toyota on each side more steering(which is a lot)
Cut the front housing out to fit electric low pinion lockers. Iím sure everyone seen that before.
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Old 10-09-2019, 05:32 PM   #4 (permalink)
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Shaved both axles.
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Old 10-09-2019, 05:33 PM   #5 (permalink)
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Braced knuckles (but I think I bent them anyways)
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Old 10-09-2019, 05:35 PM   #6 (permalink)
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What spring ends up looking like on passenger side.
Love it so far.
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Old 10-09-2019, 05:36 PM   #7 (permalink)
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Front spring mount!
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Old 10-09-2019, 05:49 PM   #8 (permalink)
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So I decided to go with a Montero trans.
03-72L. I did this so I could have small, short drivetrain! This trans has 23 spline rear output stock. I remove the bell housing, dip stick, flex plate, line fittings, torque converter, front input, from a 2wd (Iím told 4wd is same) 4 speed 03-72LE that came behind 2.0 engine Iím putting in the zuki.
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Old 10-09-2019, 05:50 PM   #9 (permalink)
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Quote:
Originally Posted by lwb86 View Post
Interested in the adapter you used to put the Dana 300 in there


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Ok
Iíll post that soon.
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Old 10-09-2019, 06:05 PM   #10 (permalink)
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Bell housing off the 03-72LE Iím putting on the 03-72L.
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Old 10-09-2019, 06:07 PM   #11 (permalink)
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Had to leave a sensor in and cut off the end of it so fluid didnít leak out. Blue sensor on the bell housing.
Rebuilt transmission while I had it apart. Had friend do it and itís working great. Still havenít wired up the overdrive yet. Like I said. I used this trans cause I wanted to be small, short, lite and front dig!!
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Old 10-09-2019, 06:09 PM   #12 (permalink)
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I had to use a 3/8Ē thick clocking ring so seal would work in the rear tail housing!!
It sits a flat with trans pan.
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Old 10-09-2019, 06:11 PM   #13 (permalink)
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Added 4.1 gear
Still stock front and rear outputs, might upgrade rear soon.
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Old 10-09-2019, 06:12 PM   #14 (permalink)
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Added sight glass cause I hate getting to these cases to check the fluid.
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Old 10-09-2019, 06:12 PM   #15 (permalink)
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Ready to go in.
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Old 10-09-2019, 06:13 PM   #16 (permalink)
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Made some shifters for it!!
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Old 10-09-2019, 06:15 PM   #17 (permalink)
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Rear housing of 03-72L
Had to drill one hole (arrow) to bolt it up and cut some off (arrow) to clock it where I wanted it.
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Old 10-09-2019, 06:16 PM   #18 (permalink)
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Quote:
Originally Posted by toyotanuts View Post


Rear housing of 03-72L
Had to drill one hole (arrow) to bolt it up and cut some off (arrow) to clock it where I wanted it.


Seal is missing from this photo but you can see where it goes. Used same one as Dana 300 input!! Fir right in
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Old 10-09-2019, 06:18 PM   #19 (permalink)
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Added temp port to trans pan so I could keep eye on it.
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Old 10-09-2019, 06:23 PM   #20 (permalink)
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Got motor where I wanted it. Steering box off a fj80 (which is awesome so far! A lot better than ifs!!) moved motor against frame. Heated header and bent towards block a least 1 1/2. ď I really wanted motor towards driver side as much as I could so drive shaft and 3rd would have room for up travel. Itís things like this I feel a lot of people donít take the time to do and make a huge difference!!
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Old 10-09-2019, 06:25 PM   #21 (permalink)
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Zuki 2.0 build mod stock


Replaced front tube with 1 3/4 dom! It pressing right inside of stock thin wall tubing. Made it air tight for air tank. Also winch mount.
Also used angle for radiator mount with two hole in the bottom to fit stock 2.0 radiator. Angle is flush with bottom of the frame. I used 1/4Ē so I could tie winch mount into it later. Also front suck down winch rope may pull against it.
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Last edited by toyotanuts; 10-09-2019 at 06:29 PM.
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Old 10-09-2019, 06:26 PM   #22 (permalink)
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Made motor mounts out of stock mount and some aluminum tube I had. Iím not the best at aluminum welding but itís worked great!
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Old 10-09-2019, 06:33 PM   #23 (permalink)
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Used a 22r water neck. Cut off Toyota flange and and made a 2.0 flange. Yes I suck at welding aluminum. But it donít leak!!
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Old 10-09-2019, 06:35 PM   #24 (permalink)
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Took a whole to get this right but this is my winch mount. Didnít want a huge jay leno bumper like most samurai have catching everything.
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Old 10-09-2019, 06:37 PM   #25 (permalink)
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What winch it looks like when Iím done!!
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