[Lucy_FJ55]

Originally Posted by apeterson

doing a great job!!! nice truck!!!

Thanks! I recently stumbled upon your build-up thread, great job! It has given me some ideas...

[apeterson]

Originally Posted by Lucy_FJ55

Thanks! I recently stumbled upon your build-up thread, great job! It has given me some ideas...

cool.... glad I could help... thinking about doing a 55 after this.... so I have been hanging out in your 55 section some.... still got a way to go on this 40 but only time will tell

[75PIG]

Nice job on the work you are doing. Enjoying the pictures. I'm just to the north of you in Richland, WA.

Good Luck!

[Lucy_FJ55]

Originally Posted by 75PIG

Nice job on the work you are doing. Enjoying the pictures. I'm just to the north of you in Richland, WA.

Good Luck!

Thanks. I noticed your recent work on your pig you posted. Nice job, keep it up.

[Lucy_FJ55]

Update:

Got the call from NAPA and picked up my head and other parts. Also spoke with Jim C. and he has finished my carb and stuff and put it all in the mail. Hee, Hee, Hee.

I was able to work on the engine today for a few hours. I finally removed the new pilot bearing that we f'ed up during install. I first tried the hydrallic/grease method because it worked so well removing the original one but this time it blasted the outer face of the bearing out and made a mess. I then tried a small bearing puller and a slide hammer and neither worked. I started to get frustrated so I grabbed a cold chisel and a small sledge and proceeded to go to town on it. I quickly removed the inner race and the ball bearings but that still left the outer race. I then used my new Dremel and about 5-6 'heavy duty' cut off wheels to weaken the outer race that was still very stuck. This took awhile and just as I was getting really annoyed I grabbed the small bearing puller again and tried it on the leftover outer race. It actually worked this time and I finally removed that SOB.

I cleaned up the mess and installed my second, new pilot bearing. Then I cleaned up the bellhousing a bit, wirebrushed all the bolts and washers, and used compress air to blow any crud out of the bolt holes. I used some threadlock and slapped the bellhousing on. Was about to finish installing the clutch and then realized I couldn't fit the flwheel or clutch parts under the bellhousing while the engine was sitting on the garage floor. So it looks like I better install the head next.

Um, and no pics. I'm having problems uploading pictures from my camera. I'll keep working on it.

[Lucy_FJ55]

I was able to upload some of the pics from my camera to the computer-but not all of them.

Pic of both valve covers cleaned up a bit. I think I may clear coat the VC and the intake manifold. Both have been cleaned up and look great. I may try to keep them looking good a little longer.

Christmas in April! The guys at NAPA even wrapped my head for me. I can't wait to unwrap it and install it.

I also got a chance to go explorin' last weekend. This spot is 30 minutes east of town.

Carlos

[Lucy_FJ55]

Got in some more work today on the engine. I was able to finish cleaning the block surface, head bolts/threads, and bolt openings. I unwrapped the head and installed it along with the OEM gasket and carefully torqued it down. I installed some of the accessory brackets and then began working on the coolant system. Replaced the coolant hoses and clamps as well as replaced the gaskets for the waterpump/thermostat housing. Replaced the thermosatat. Installed gas lines and waterpump.

Need to decide if I am going to use the oil cooler. The newer water pump has a hose that connects to the oil cooler but the old water pump does not. So I have to decide which set up to go with...

Sorry, still having problems with the damn camera.

[tyama]

Great details! Keep the info coming. I'd like to try my hand at this sometime in the not too distant future. Any thing you can think of how you went through the building process would be nice. Best of luck!! ty

[Lucy_FJ55]

Well, I decided to go with the orig. water pump and oil filter housing from the '77 engine because it seems to all fit and work well with each other. This will eliminate the oil cooler but I should have enough room for the fan and it should not hit the radiator. This was my concern with using the newer setup from the '81 engine. It would have apparently been too long.

So, I have installed a couple more accessories onto the donor engine and am figuring it all out. I may have to measure and buy some custom/fitting belts for the engine. I have replaced all the coolant hoses with new ones and new hose clamps. I have received all my parts back from NAPA and also my carb and dist. from Jim C. The carb looks great and I can't wait to start this engine!

Of course, now that I have all the parts I am not able to work on the rig. I'm taking off for Hawaii foe a few days. Yep, I know- BOO HOO! :( I still am not able to post pics, so hopefull soon.

[Lucy_FJ55]

Howdy everyone, back from vacation. I was finally able to download some pics so here are a few...

First pic: Head after install.
Second pic: Another head pic.
Third pic: Pic of the new thermostat, fuel lines, etc.

I was able to clean and install the pushrods and valvetrain last night. More updates and pics soon.

[offkilter]

Welcome "back" Carlos -nice to see your progress with visual aid. I am still looking forward to the day when thee almighty pristine pig hits the pavement once again. good luck

[Lucy_FJ55]

Got a little more done on the piggie today.

1st pic: OEM starter on top and gear reduction starter on bottom.

2nd pic: New starter installed, I still need to figure out the wiring/connection.

3rd pic: Pic of the clutch fork with the new throwout bearing pressed on. I made a last minute trip to NAPA in order to see if the machine shop was open and able to swap the throwout bearing for me. I got there and they imediately went to work on the throwout bearing/clutch fork. The guy told me there was no charge and I tried to give him a couple dollars but he wouldn't take it.

[Lucy_FJ55]

1st pic: Oil filter bracket from the '77 engine, all cleaned up and a new oil filter installed.

2nd pic: Also got the flywheel and clutch disc/pressure plate/clutch cover installed. I forgot how heavy all that crap is to hold in place and try to install/tighten bolts to align everything together. Took a couple attempts bolt it is now waiting for the transmission/transfer case.

3rd pic: Also got more of the new hoses/clamps installed and the alternator is sorta installed.

[Lucy_FJ55]

Ended up clear-coating the valve cover and intake manifold before installing. Here are a couple pics of the parts masked off, being painted, and finished.

[Lucy_FJ55]

More pics...

1st pic: The header had a few scratches and scuffs in it. I ended up cleaning it and laying down some fresh black high-temp paint. Looks good-and is ready for install.

2nd pic: While my parts were all drying I stopped by NAPA to have them help with my clutch fork/throwout bearing. While waiting I checked to see if they had nuts and washers for the new header/manifold setup. They hooked me up with these.

3rd pic: So, I installed the header and manifold after they were dry. Everything looks good but I wonder if I will have problems with leaks?!

I would like to slap the carb on tomorrow and maybe attempt to install the trans/tranny, which I hear can be a PITA.

[Lucy_FJ55]

Another pic, up close- because it just looks good.

And then I took the dogs out for a cruise in the evening...

[n2666s]

Carlos, awsome work..love the way your pig is coming together<cheers> P.S. send email to Man-A-Fre regarding your rear bumper and they no longer make them, they did give me the email addy of the guy that made them for man-a-fre but he did not answer to my email :(

Lou

[warrior_1515]

Great Work!!!

I'll make some time to stop by and check out your progress.

looks great

dave

[Lucy_FJ55]

Thanks Lou. That sucks about the guy not emailing you back. He makes some great products.

Originally Posted by n2666s

Carlos, awsome work..love the way your pig is coming together<cheers> P.S. send email to Man-A-Fre regarding your rear bumper and they no longer make them, they did give me the email addy of the guy that made them for man-a-fre but he did not answer to my email :(

Lou

[Lucy_FJ55]

Well, I had to remove the intake and headers due to poor fit. The intake is thicker than the headers and will not make a tight seal. I have already had the intake milled because it had been slightly warped and I am concerned about milling them more. Or maybe the intake manifold could be drilled out a little thinner at the bolt openings. I am not sure what I am going to do about it. I have also heard of folks cutting washers in half in order to compensate for the difference of thickness instead of milling. Here are some pics. Anybody have any suggestions?

[warrior_1515]

Any updates?

[DWitcher]

Where did you find the gear reduction starter?
Do you have a part #?

[Lucy_FJ55]

Originally Posted by warrior_1515

Any updates?

Can't stop wrenching...

I'll post up a progress report soon.

OINK! OINK!

[Lucy_FJ55]

Originally Posted by DWitcher

Where did you find the gear reduction starter?
Do you have a part #?

I called CruiserDan and he shipped it to me. They're stock/OEM on later 2F's.

Toyota Part No. 28100-60070-84 (Remanufactured Toyota part)

(As per the box)

[DWitcher]

Cool, Thanks. What kind of pricing do those run?

[Lucy_FJ55]

Originally Posted by DWitcher

Cool, Thanks. What kind of pricing do those run?

Mmmm, I don't remember. BUT, it wasn't much more than the regular starter and I got a good mud/TLCA discount.

[Lucy_FJ55]

Well, I got a little work done on the pig over the holiday weekend. Thanks mainly to a few good friends. Thanks guys-you all know who you are.

I finally figured out the header/intake mess. I used a combination of washers, both different sizes and thicknesses. I cut some of the washers in half and some I had to grind down a bit. It took awhile but I think it will work well. We'll see. That allowed me to finally move on to the next step.

I spent some time cleaning up the transmission and transfercase before I tried installing it. It was a mess. I was able to wrestle that on by myself and was so stoked that I called up a few friends and convinced them to help drop the engine/trans/tranny in. Guess what? They actually showed up and its in!

Another buddy came over and helped me figure out how to connect a couple of the newer accessories to the '77 wiring harness. So the gear reduction starter is basically connected, I used the old ('77) alternator, I swapped in the newer coil and ignitor (no ballast resistor) which works with the newer distributor ('81), installed the SS double battery tray I have been holding onto, and threw in a battery to check the eletric/systems, installed the fluid heat riser for the header, tossed the carb on, connected fuel lines, connected coolant hoses, etc.

OINK! OINK! Here are a couple pics...

[Lucy_FJ55]

1st pic: SS battery tray-great for holding tools. Real nice/high quality product.

2nd pic: After installing the battery tray I realized that the new windshield washer bottle/deal needs to be slightly modded or relocated inorder to fit on the inner fender. I'll deal with that soon.

3rd pic: Check out all the space in the garage. My 'better half' is already inquiring about parking her car in the garage. I better roll in another 'project'.

[Lucy_FJ55]

A little more progress and a bit of a setback.

I managed to install both driveshafts, cleaned and painted the fan shroud, and then f'ed up my fuel connection to the carb.

When I tried connecting the two fuel hard lines to the carb I stripped one of the 'nuts' and then its corresponding 'nipple' on the carb. I don't have a tap and die set so I tried a small triangle chisel to 'fix' the threads, and of course I f'ed it up worse. My friend then advised me to cut the stripped end off, and I did, but now it doesn't seem like it will create the leak-proof seal it once had. It's too short. ARRGH.

So I am looking for a replacement and I'm not exactly sure how I am going to repair the threads inside the 'nut' that is basically attached to the hard line/difficult to remove. Anybody have one of these nipple-do-dads or have any advise on cleaning up the threads on the inside of the nut?

[Lucy_FJ55]

I also tried dealing with another setback that popped up during the engine install this last weekend. We were having clearance issues while squeezing the engine back in place. The transmission top was catching on the tunnel edge and we decided to pop the tranny top plate off as a quick solution. I realized just before I removed the top that it was under pressure somehow, I peeked and saw a couple springs and removed it cautiously, only to remove it and lose the THIRD spring I wasn't able to see. Anyhoo, short story made even longer, I dropped the spring inside the tranny- I think. I looked everywhere for the spring and can't find it so I assume it must have fallen into the tranny.

So I drained the tranny, was planning on it anyway. I grabbed my telescoping magnet, swapped out magnets, and somehow I broke it. DOH! Fortunately the magnet end did not end up also falling inside the tranny. I then grabbed a light to see if I could find the spring- and could not. So, if I can't find the spring I then bolt it back together, top it off with oil, and run it, right? And hopefully the gears just pulverize it and I just need to find a new one? Any ideas/comments?

Pic shows the underside of the tranny top plate with the two remaining springs and my finger is pointing to the gaping indentation that I assume housed the mysterious THIRD spring. This is getting a wee bit annoying...