I agree that V8s aren't kind to clutches especially
If the driver slips it, but a 1KZ clutch has a decent clamp load of 780kg, and as long as the differential ratio is nothing stupid high like my CJ7's 2.73 ratio, it will take pretty good abuse. SuhaibKiani is running one in his rally truck and it's holding up real good so far. The key in this case is a reasonable diff ratio. 4.1 and 3.7 won't load the clutch too much. A McLeod twin disc clutch would be ideal but it's borderline unaffordable and I doubt they make them for the 1UZ.
Just stick with the basics for now. You just need to install the engine and transmission. Built HD transmission and high stall converter would need to be ordered from the USA so put that on hold for now.
From a driver's perspective auto is best way to go off road. Smooth power delivery and awesome control over rough terrain. In my opinion it's definitely a better choice for a shikar vehicle. Are you sure your dad wants fulltime four-wheel drive? That's the kind where some power is always delivered to the front wheels and the center diff lock allows 50/50 power split front and rear when you engage low range. Most purists (shikaris) prefer selectable four-wheel drive where the front wheels get no power until 4x4 is engaged, if only because it's a simple system. In any case, if you want to retain the original full-time four-wheel drive of the range, then you'll have to either keep the original transfer case or swap out to a pricey 80 series Land Cruiser transmission.
It would be a lot simpler to go for a Prado manual box. It's a tried and tested combo. Not crazy expensive like your other options either. Not fulltime 4x4 though.
Peshawar is definitely a better place for this kind of work but consider Rawalpindi too, especially since it's closer. SuhaibKiani had his 1UZ powered FJ40 prepared at City Saddar road and it's probably the most reliable and beaten upon 1UZ vehicle I know of. You should contact him for guidance.
Sent from my SGH-I897 using PW Forums mobile app