1976 FJ40 South American Spec “Restored” in Colombia, fixed in USA.

[BeerM3]

It's so clean and shiny!! Thanks for all the documentation work you're doing here. It's a great walk through, and I'm not saying that just because I have a '76 as well! Impressive wiring skills too. I cheated and had Coolerman make me a new rear harness.

 

[Ackcruisers]

Thanks, man. From not knowing much about my ‘76 FJ40’s wiring to restoring two complete harnesses and building all sub harnesses and rear harness, it’s been a learning experience. It’s very time consuming when you go through a harness for the first time. I now have a bachelor’s degree in 1975, 1976 and 1977 harnesses. For the record, I reached out to Coolerman to have him go through my harness but his wait list was too long.

 

[Ackcruisers]

Routed rear harness in truck. Happy to report it fit exactly as the one Toyota made. When making your own, do not omit the split plastic loom in specific sections around the rear section of rear harness. They add durability.
View attachment 2281526
Installed OEM L and R tail light assembly. #81560-60110 and #81550-60190.

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OEM clip for rear section of rear harness to frame.
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Used marine grade (Ancor Marine) clamps on front section of rear harness to secure harness to inside frame rail. Used 8MM x 1.25 bolts from Overland Metric. The powder coating required re tapping frame screw holes.

Decided to change the rear wiring harness mounting to frame rail. Rather than use the Ancor Marine clamps, I went with these OEM clamps #90461-10221 available from Toyota.They fit perfectly around the front section of the rear harness.

 

[Ackcruisers]

Installed fuel separator and check valve then routed vapor hose to engine bay. Painted charcoal canister #77740-80012 and bracket. Reinstalled cover no more fumes.

 

[Ackcruisers]

All wiring after install works exactly as bench tested. The fuse panel was purchased from City Racer.

 

[Ackcruisers]

Just went through process of installing new reverse light switch OEM #84210-57012 (24mm). The previous switch had no continuity when switch was activated. Since switch has two soldered wires on terminals on the back, to install required removal of transmission cover assembly.

 

[Ackcruisers]

Installed the OEM dome light #81240-90300. Since my 1976 FJ40 had no hole at the top of windshield, I drilled 1/4” hole and fished wire from harness up to top. It requires the build of 3 sections outlined here.

It was so tricky to reinstall the soft top channel after removing it without taking the entire top off the truck. A classic case of carving out an hour to do the work and it taking twice as long.

 

[Ackcruisers]

Installed new steering Coupling Assembly Flexi #45230-36010 aka “ rag joint”. Also, installed main shaft Cover seal #45292-60011, steering Bearing #90363-18038.

 

[Ackcruisers]

Reinstalled Vintage AC System and its wiring harness. Changed location of a few wiring items and ran LR wire from heater switch to replace purple B+ wire. Custom made firewall gasket to avoid using silicone as suggested by manufacturer.

 

[alex e]

Seriously clean vehicle. Very nice.

 

[Ackcruisers]

Installed glove box gasket #55549-90300 and wire OEM # 55508-30020 to hold door. Wire is still available from Toyota click here. It’s the small details that make the difference.

Also ran complete check of cooling system following the replacement of thermostat and housing. You can see full thread here.

 

[Ackcruisers]

Installing Brake Pedal Return spring and Parking Brake Spring purchased from SOR (part numbers in image below, the one on right is for parking brake). Since my pedal bucket assembly is different than US trucks, I’m not sure where the return spring mounts on dash near steering column. I know where it connects on pedal. I believe I need to drill hole but was hoping @Dizzy or @BeerM3 any chance you can post picture of where theirs is mounted.

Parking brake spring install was clear where it belongs.

 

[Brian/99uzj100]

Great build. Here ya go:

Hole is just to the right of the steering column when looking down at the pedals.
Pic is looking up from the pedals.
Don't ask why I have 2 return springs, because I don't know...

 

[Ackcruisers]

Great build. Here ya go:

Hole is just to the right of the steering column when looking down at the pedals.
Pic is looking up from the pedals.
Don't ask why I have 2 return springs, because I don't know...

View attachment 2316569

Thanks man. Appreciate it. It appears your springs are attached to a hole on your pedal bucket assembly vs. hole in dash. On my truck the steering collar just bolts to dash. I’ll have to improvise like I just did for the clutch pedal return spring. The clutch pedal return spring has different part number on SOR but it is exact same as brake pedal return spring.

 

[samatulich]

Not sure how I have missed this thread. Really nice work, as said by others, very clean.

 

[Ackcruisers]

The details on our FJ40‘s are what makes it interesting to put together. Installed the Wiper Motor Harness Protector for when folding down windshield. The wiper motor sub harness #82370-90312 and the grommet is #25 below and has part #82818-60010. These are NLA but City Racer has them here is link.

 

[Ackcruisers]

Just upgraded my washer fluid nozzle to OEM #85035-60050 still available from Toyota. Now the water actual hits windshield as designed by Mr. Toyota.

 

[405]

Any more updates on your truck? Looks like you did a great job sorting it.

 

[Ackcruisers]

Thank you. I’ve done so much but have contributed to various threads showing the work. I’ve been meaning to update and will do one of these days.