opinions on building a FUSO FG from a FE

#1
Looking for thoughts and opinions on converting a FE to FG 4x4. The FE are reasonably priced in the 2000-2006 model years but the comparable FG seems overpriced (US Market). I found a couple of FG 4x4 trucks in scrap yards and thought about acquiring the front axle and bits and maybe using a aftermarket transfer case. The scrap yard will not sell the transfer case without the transmission. Anyone done it?

Thanks,
RJ
 
#3
Hi Kevin,
I assume the FUSO will have the same frame rail width problems as the Isuzu. The solution on the crawler hauler was not pretty and I would be concerned with the bending load of the brackets they created to handle the 3 inch width problem between axle and frame. I look forward to following your build.

forum.expeditionportal.com/threads/160699-NPR-4wd-conversion-and-camper-build-thread?highlight=isuzu+project
 

SkiFreak

Expedition Leader
#4
This topic has been discussed previously, but to summarise...
You need to be mindful that the chassis on a FE is different to that of the FG, in that the FG has quite a large step down behind the gearbox.
The reason for this is to lift the cab high enough to give space for the front diff. The FG diff's pumpkin is pretty central, so without enough clearance it will hit the sump. With a different diff you might have an easier upgrade path, if the pumpkin is offset.
 
#5
Hi Kevin,
I assume the FUSO will have the same frame rail width problems as the Isuzu. The solution on the crawler hauler was not pretty and I would be concerned with the bending load of the brackets they created to handle the 3 inch width problem between axle and frame. I look forward to following your build.

forum.expeditionportal.com/threads/160699-NPR-4wd-conversion-and-camper-build-thread?highlight=isuzu+project
I've since redone all the leaf spring mounts. I wasn't concerned with their strength so much as they were ugly and the rear mounts were welded to the frame. The front mounts were welded too but to the front section, separate from the main frame. Either way I redid them to add a couple inches of height, more caster and to make them look nice.
 
#6
Sorry JavaJoe, I actually missed your front updates in the mix of pics for the rear suspension changes (page 14). Do you think you have enough clearance/travel between the diff and engine? Did you need to make changes to the steering? I guess I should ask this on your thread and read it more thoroughly :)
 
#8
RJ,
Will know more when I get into it. Still deciding if I want to go custom leafs with my 03 supers or go to a coil with the newer axles and a custom radius arms.
Kevin
 
#9
Sorry JavaJoe, I actually missed your front updates in the mix of pics for the rear suspension changes (page 14). Do you think you have enough clearance/travel between the diff and engine? Did you need to make changes to the steering? I guess I should ask this on your thread and read it more thoroughly :)
I wanted a bit more differential to engine clearance too so that was a factor in raising it some.