Found this....F engine block flush/ muriatic acid Might be on the right track or might possibly have to remove a rear freeze plug, we'll see
Builds 1966 FJ40 Frame-Off Build (3rd Generation Owner) (1 Viewer)
- Thread starter Jason Reed
- Start date
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I would pull all the freeze plugs and then take it to a machine shop and have them clean the block. I think most dip the blocks in something which cleans them. Not for sure on that thogh.
Yeah, I'm going to attempt to get some muriatic acid up in there but pulling the rearmost freeze plug may be next. This 66' only has 2 freeze plugs on the drivers side while I think some of the later blocks had 4. The nearest freeze plug isn't very close to the drain unfortunately.
Worked on this a few more hours this morning...fluids drained, driveshafts out, transfer case out, transmission out, clutch cover and clutch disc out.
Transfer case innards are pretty blackened and nasty, oil looked OK though but a bit low.
Clutch disc release fingers are EXTREMELY worn down. Either the clutch was adjusted incorrectly or an operator was riding the clutch pedal
How is sits currently
Transfer case innards are pretty blackened and nasty, oil looked OK though but a bit low.
Clutch disc release fingers are EXTREMELY worn down. Either the clutch was adjusted incorrectly or an operator was riding the clutch pedal
How is sits currently
Started draining fluids from the engine, transmission, transfer and diff. All the gearboxes were low and the transmission was pretty plugged up with small metal shavings, we'll see how that looks during tear down. Then there was this when the engine drain plug started to get loosened...
There was easily several ounces of coolant resting in the bottom of the pan and the oil has obvious water contamination. I'm guessing failed head gasket at this point probably as a result of an overheat related to the plugged coolant passages in the block.
There was easily several ounces of coolant resting in the bottom of the pan and the oil has obvious water contamination. I'm guessing failed head gasket at this point probably as a result of an overheat related to the plugged coolant passages in the block.
Flywheel came off today, it's hard to see in the pic but the surface has some really serious heat cracks, possibly the worst I've ever seen. New flywheel, clutch disc and pressure plate are one hand for replacement.
Tore into the transfer case next, again really blackened internals throughout with some evidence of water intrusion at some point. The parking brake assembly actually looked pretty good and then I got to the backing plate. The backing plate bolts and rear output bolts had been replaced at some point, probably to address a leaking rear output seal. The backing plate bolts were too long (bottomed out into the output) and the backing plate itself was just rattling around on the output.
Noted that the front output flange nut was completely lacking the required cotter pin to keep the nut in place. In addition to that, the front output seal was very, very bent and installed too deeply into the output cone.
It's bent
Tore into the transfer case next, again really blackened internals throughout with some evidence of water intrusion at some point. The parking brake assembly actually looked pretty good and then I got to the backing plate. The backing plate bolts and rear output bolts had been replaced at some point, probably to address a leaking rear output seal. The backing plate bolts were too long (bottomed out into the output) and the backing plate itself was just rattling around on the output.
Noted that the front output flange nut was completely lacking the required cotter pin to keep the nut in place. In addition to that, the front output seal was very, very bent and installed too deeply into the output cone.
It's bent
Got the output separated from the case and immediately noticed this....there should be a roller bearing for the 4WD output shaft here. Oddly enough, I didn't find any needle bearings in the bottom of the case. Fortunately this hadn't worn so far as to actually damaged the inner bore of the output shaft.
Case is all apart, pretty gross inside
Tore the vacuum 4WD shift assembly down next. The 4WD indicator switch should probably be replaced but the diaphragm on the vacuum housing is in remarkably good shape
Vacuum shift assembly
Case is all apart, pretty gross inside
Tore the vacuum 4WD shift assembly down next. The 4WD indicator switch should probably be replaced but the diaphragm on the vacuum housing is in remarkably good shape
Vacuum shift assembly
Here's a shot of the idler shaft from the transfer case. It's shows fairly "normal" wear in my opinion. Full rebuild kit is sitting on the shelf but the transfer will require some serious cleaning before any of that occurs.
- Thread starter
- #69
Ross is doing a fantastic job on this, all while I'm learning the history behind my family's FJ40. Maintenance was neglected as this set outside for years and driven very infrequently until recently (maybe 2,000 miles in past 5 years). Vehicle only has 68,000 original miles for a '66, but can't wait for the restoration back to life 
- Thread starter
- #70
Meanwhile back in California, all the new Steel Parts were delivered today (left/right quarters, inner/outer rockers and wheel wells). Also made the decision today to do the FJ40 in Toyota Spring Green (paint code T-1028). Just can't steer away from that color. Lovin it...
I only had a very small amount of time to look at some parts this morning before heading to work early. All the parts for the transfer case are soaking in the parts washer now. I did take the time to clean up the 4WD output shaft, not very pretty. Water doesn't mix...
The lower shaft is from the 66' the upper shaft is from a 70' for comparison purposes. I won't run the 66' as I feel the bearing surface and engagement splines are too compromised at this point. Replacement time
The lower shaft is from the 66' the upper shaft is from a 70' for comparison purposes. I won't run the 66' as I feel the bearing surface and engagement splines are too compromised at this point. Replacement time
Started cleaning up the transfer case assembly and parts this morning before heading off to the real job. Internals are currently clean, case is on it's way...look how black the interior is. I'm not sure if I've seen a transfer case this color before.
Out of the parts washer and getting there...
Out of the parts washer and getting there...
Pulled the top shift cover from the 3 speed transmission today after bolting the trans up to an engine stand. Again, obvious signs of water intrusion here. 1st gear might be salvageable and it might not. We'll see upon teardown
BretwithoneT
SILVER Star
What do you have in your parts washer for cleaning? My transfer case looked about like yours and it took a month of scrubbing.
It's "Pearl" brand solvent and it's petroleum based. You can usually get it at Napa in a 5 gallon container for roughly $75 or so. From what I've found, some solvents are definitely better than others and I'm not a fan of water based stuff.
Not to jump ahead, but what's your plan for the frame? I am almost there myself and debating options...
Yes, it's going to be blasted and powdercoated locally. I've had VERY good success with powdercoat parts on my 69' FJ40. The prep work is absolutely key.
Just to consolidate parts, I cut the old bearing out of the transfer case mainshaft with a high speed carbide bit. In my experience, this is the best way to remove these as the bearing is pressed into a blind hole and the tolerance is actually pretty tight.
Gotcha!!
Jason, this is OFFICIALLY the first replacement part on this entire rebuild! I had to use a press to get it to seat correctly. Yeah, tight.
Gotcha!!
Jason, this is OFFICIALLY the first replacement part on this entire rebuild! I had to use a press to get it to seat correctly. Yeah, tight.
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Transfer case parts are done.....now they need clearcoat. Jason, if you're thinking about red powdercoat on some of these parts the PTO cover might be a good candidate also. If not, I'll clear it. I probably spent as much time cleaning the 4WD shift assembly as I did the entire case. Took forever!
