1973 FJ40 "Herman"

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It has been two weeks since I finished the brakes and the tires. I am going to put the new springs on this weekend and begin Project Stop Leak 2013 but here is the update so far:

The brakes weren't bad. As long as you have the tech manual and a second set of hands for re-installation it isn't to hard. Definitely more difficult than disc brakes but not undoable for an average shade tree mechanic. It doesn't take any advanced skills or anything. As far as cost it was expensive, but I replaced everything but the master cylinder so...Bleeding the brakes was easy with a vacuum bleeder to do most of the work. Once I had it pretty well bled I started up the 40 and had the wife push the brakes while I did a world tour and bled each of the cylinders again. I think this was necessary because of the booster and it being vacuum assisted. Is this true?
The Sears brake tool kit turned out to be a huge waste of money. The only thing I used was the brake adjustment tool and I had to grind that down to make it work. Just go get an adjustment tool from the local parts store and a pair of needle nose vise grips and that should be all you need except for some basic everyday tools. The one tool I wish I had was a 10mm tube wrench. I used a standard 10mm combination wrench to remove the brake lines and ended up destroying two of the line fittings. So definitely get one of those before you start the brake job.
It appears the front brake cylinders have been discontinued. I was able to find a front PS Set but the DS set is no where to be found. So I ordered up a set from SOR. On the outside they appear very similar to the OEM parts. If I were to do this again I would order all the cylinders from SOR and save a lot of money, but I was really nervous about using Non-OEM cylinders after some previous members posted their reports. Time will tell how they hold up but so far so good.
The wheels turned out great! I had the local Goodyear store remove the old tires which they estimate to be from the year 1989! So although there was lots of tread left it was definitely time to replace them. In case you missed it I had the rims then powder coated to the closest original gray I could find and the rims were then wrapped in Pro Comp Extreme MT2 at 31x10.5R15. The only rubbing I get is the DS front wheel when I turn hard left. It appears to be rubbing on the sterring linkage. It is only on full left so I have just stopped going hard left to prevent this. Hasn't been an issue. I love the way they fill the rear wheel well and hopefully the new springs won't lift it up too much. Everyone now comments on the wheels and I feel a lot better driving it. The steering is more stiff at speed and I'm confident Herman will take me anywhere I need to go.
I will be posting some pictures about any leaks I find this weekend and hopefully I can stop most of them. I am afraid either my rear main seal or the transmission input shaft is leaking badly. When I got back from a long trip the other day Herman dumped a nice size puddle of what seems to be regular oil all over the ground. But it kind of smelled like gear oil too. So I need to get in there and clean it up. As always, comments and advice is welcome!:beer:
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***WARNING*** Do not jack up the 40 and place jack stands under the axles when swapping leaf springs. This compresses the springs and when you remove the last bolt the resulting un-compressing is catastrophic. You could seriously be injured! I have done the rest of the swap without any jack stands and seems to not be an issue. I have had to jack up the frame to remove the old u bolts so I am thinking jack stands under the frame would be fine. Just because there are no moving parts doesn't mean you can't get hurt! It felt like getting hit by an NFL Linebacker or a full speed Prop (For our Rugby fans). Doh!


In the process of changing out the springs with new no-lift springs from Man-A-Fre. New shackles, pins, and U-Bolts to boot. Man-A-Fre sent me the wrong bushings and I didn't order new ones for the pins. It was a complete new guy mistake. So after waiting a week I got the correct bushings and the 8 additional ones I would need. Normally, they wouldn't charge me shipping for the replacement parts but since I ordered "additional" parts they charged me 17$ to get me what I needed. Right, wrong, or indifferent that really made me angry. I already paid 200$ freight shipping to get the springs to me I guess I thought they would cover the shipping to get me the rest of the way there...
Additionally the new springs "center nut" doesn't fit inside the stock U-Bolt plate hole so I had to go buy a bigger drill bit to get that to work. Another 20$.
After all of that I've decided I will not be doing further business with Man-A-Fre. A full report and photos will be posted when I am done with the job. Hopefully I will not have any firther issues...
 
***WARNING*** Do not jack up the 40 and place jack stands under the axles when swapping leaf springs. This compresses the springs and when you remove the last bolt the resulting un-compressing is catastrophic. ). ...

Your supposed to let the front end droop before placing the axle jack stands. No weight on the suspension is what your after.
 
Well, I finished up the suspension work on Friday. My Dad and Brother were in town so with the extra muscle we were able to get everything back together. The difficult part being getting the axle "pin hole" to line up with leaf springs "pin". Just had to get the axle off the floor and move the axle since there was no moving the leaf springs. I greased up the pins with mobile 1 synthetic red and everything seems to ride just fine. I will have pictures later today or tomorrow. Except for nearly getting killed by a unspringing spring the project wasn't difficult. It was easier then the brake work for sure. It brought my ride height up just a bit but that was expected since it had been on 40 year old springs. Keep on keeping on...
 
Here are some photos of how Herman sits now. The front is slightly higher than the back but I think and am hoping that it will settle in due to the weight of the engine. The front leaf springs had 7 leafs, the back only six. This is how the stock ones were too. As a reminder, the springs are Man-A-Fre no lift springs with their grease-able pins and shackles. Pro-Comp ES3000 shocks. Stock rims powder coated wrapped in 31x10.5R15 Pro Comp Extrem MT2s. Thoughts?
As for the spare it is a Phillips 66 tire and I want to keep it for nostalgia sake, hence why it doesn't match.
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Nice work phares! Mine sits similar.. the front has not settled much since last August. I'd also be interested in suggestions!
 
longer shackles in the rear solved my sagging problem - just sayin'
 
Hey Phares-hows Herman coming along?
 
Herman is coming along great! Pretty much just been driving him around town the last couple of months enjoying my recent upgrades. I'll be heading to Cars & Coffee tomorrow with some other 40 owners so that should be a blast.
I got a replacement reverse light since I broke the glass out of the stock one. It isn't the same so I will be hoping to get the original repaired at a custom glass shop.
Thanks for asking!
 
Thanks! Over the winter I have TRE plans along with trans and transfer case work. The baby is due early December so we will see what actually gets done. And I think I just found a 1980 pickup I'm going to look at this week so lots of exciting things happening!
 
I had credit with CCoT so I ordered a bunch of stuff up for Herman. A new DS front marker light to replace the old corroded one, new hood-windshield bumpers to replace the old cracked ones, transfer case rebuild kit, and an engine gasket kit. I was really looking for a transmission rebuild kit but they were out. Supposedly they will have more in January but we will see. I checked out other sources but have only been able to find gasket kits.
I checked out that 1980 SR5 Long Bed pickup and have decided to get it. So I sold the 2010 Tacoma back to the dealership for what I considered to be a good price and will be picking up the pickup this weekend or the middle of next week. Pictures and a thread for that will be started in the appropriate section. By freeing myself of the monthly payment I should be able to put some more money into Herman. Once the pickup proves it's worth and reliability I am considering pulling the entire drive train from Herman and hauling the body out to the Mad Canadian's shop for body work. But I haven't talked to him about this yet so who knows. But the drivetrain is definitely getting worked over the Winter. My time now is spent researching the rebuilds on the Tranny and Transfer case. If anyone know any great threads please post away.

Winter Plans:
Tie Rod Ends replaced and the vehicle Aligned
Transfer Case Rebuilt
Transmission Rebuilt
Engine Gaskets and Seals Replaced
Refurbish Heaters
Radiator Refreshed
Carb Rebuild
 
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The baby has arrived, and wouldn't stop crying this afternoon, and I believe in the dependability of the pickup so work is continuing on the 40. I've had the tie rod ends laying around for a bit so I figured I would get started on operation better steering. New TREs, shimmy dampener and rebuilding the center arm located by the front bumper. If there is anything else I should look at please let me know. I really need to rebuild the steering box in the DS wheel well too. Attached is a picture of the steering relay and tie rod out of the truck. Of course an alignment job is planned at the end. Advice is always welcome.
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On the baby crying or the truck? :-)

Congratulations dad! So...whats the name? Hows mom doing?pics or it didnt happen?!
 
New tie rod and steering relay rod ready to go in. And the old TRE and steering damper. This job turned out to be the easiest one I've done yet. The hardest part was getting the old TREs out of the rods. Also, realizing that some of the pieces were left hand threaded sure helps. I set the rods to the length established in the FSM and will be heading to the alignment shop on Thursday. Herman drove around the block no problem. Rebuilding the center arm was easy also. It took four hands to compress the spring and get it back together but nothing extreme that couldn't be accomplished by a beginning mechanic. I did have to adapt the pitman puller I bought from advanced auto to get the steering linkage (technical name forgotten) off the center arm using my grinding wheel but it popped off no problem. The results are amazing. The steering has tightened up and it handles great now. I don't feel like I'm driving in a 50s movie in front of a blue screen anymore. If your steering is loose I highly recommend this update. I'll post more photos tomorrow. The ironman steering damper isn't perfect. The taper is not steep enough to fit the stock holes. The cruiser corps center arm rebuild kit was nice. I reused some of the old parts but it was high quality.
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Engine started heating up yesterday so i changed the thermostat and flushed the radiator. My father helped me un-bow the valve cover and it tightened up much better. So hopefully I fixed that problem. The off throttle whistle is still there so next is pulling the intake/exhaust manifold...
 

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