Builds 1978 FJ40 Mustard Yellow - almost perfect thread. (1 Viewer)

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@SNLC that was definitely a fun project! Stressful too because there was so much we both wanted to do to the truck but time was not our friend. Maybe it needs a v2 build as well....

Yeah, I’ll drive it out there for you......
 
Perhaps,

But I'm just saying it may have crawled out on it's own. If it was 90 out as you say, it would not have gone as many miles as it did.

Was the drive end sheared?

Regardless, great work...

And a question on the hfs and the new shocks... was it a huge improvement? (Did you drive it before the upgrade?) It was my first hfs install as I liked the rear wheel centering, military wrap and shackle angle but didn't care for the stiffness of the shocks.

The first 1” of the cable was bent at about 60 degrees by the time I got it out. The cable broke 2-3” from the cluster due to the bend.

when you routed into the tub you went under the main harness and not over it. This makes for a S curve in that tight area.
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The HFS shocks are not very stout. The bilstien do their job much better. Love the HFS springs but unfortunately they only sell them as a kit and the shock is not my favorite.
 
I need to correct the fact that I thought the beautifully restored alternator from @FJ60Cam was bad.

My mind was thinking that if the alternator was not showing CHARGE voltage at the output then it was not working. He sent me a new rebuilt unit and it was doing the same thing. Doh.

Turns out the non-OEM s*** box regulator was dead. If it’s not working the alternator won’t turn on. Ugh
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Sorry Cam.

Just this morning @ToyotaMatt messaged me telling me that my non-OEM regulator was ugly and I needed one of his units.


I declined but then had to call him back today to tell him he too was right.

So, there you have it. Forward.....
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Emergency backup?
 
I need to correct the fact that I thought the beautifully restored alternator from @FJ60Cam was bad.

My mind was thinking that if the alternator was not showing CHARGE voltage at the output then it was not working. He sent me a new rebuilt unit and it was doing the same thing. Doh.

Turns out the non-OEM s*** box regulator was dead. If it’s not working the alternator won’t turn on. Ugh
View attachment 2202598
Sorry Cam.

Just this morning @ToyotaMatt messaged me telling me that my non-OEM regulator was ugly and I needed one of his units.


I declined but then had to call him back today to tell him he too was right.

So, there you have it. Forward.....
View attachment 2202599

@ToyotaMatt ‘s OEM regulator even comes with a sweet old school part box. Awesome.
 
NipponDenso OverNight 24 hour shipping .....

Nothing Else matters except 13.8v Volts B+
Charging once again , by Lunch Time Friday !




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denso pic - Copy.jpg
 
Cold and wet but I’ve got a day they are not working on my shop to get Mustard 78 up on the lift and get the last of Oregon out of the frame.

I like to use air first and then water so there is not much mud to deal with.

I’ve got to go to a meeting and let this dry then Fluid Film is going down

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I used my new cutoff tool to zip off the extra long spring pins I used for the front caster shims. Total pimp.
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I bought a bulk fluid film applicator from Amazon a few months ago. This lays down a
Thinner more uniform spray than the cans. It takes about 1/2 of the spray bottle to get it good.
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Man. Doing the fluids on a lift.

Man.

So, I drained the Tcase and started cussing that Valvoline quick change place again

There was only about a cup of fluid in there. No shavings though so I only used a few choice words.
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Then I cracked open the transmission and a bit over a gallon of fluid came out.
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Damn. Not good. This means the seal between the transmission and the tcase is out and while driving the tcase fills up the transmission.
I remembered @orangefj45 posting last week he had some used ones. I called him and he got me one on the road today for Saturday delivery. This will be a temporary fix until we dive into Mustard 78 v2 later in the year.
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Last thing for the day.....I picked up the Real Steel tailgate insert and the cowl plug from
Powder Keg. The color match was spot on. After I polish the cowl it will blend right in
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I also got John a second Licence plate holder so all he has to do is change the plates over
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Love the OSHA approved. . . . . er in mean washing machine tub fire tub!

Nice Touch

It’s pretty open in the shop right now. No doors. One wall not up and it was COLD today.
That is a solo stove. One of the best toys I own.
If you look at the lift picture though you can see the cast iron goodness that will be the permanent heat source
 
Happy Friday all.

The punch list is getting very short on Mustard 78.

One thing I wanted to do was give this paint a final correction and polish

I’ll get some out of shop photos this weekend, but you can really see how a good Polish and wax with the Griots orbital made it pop

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side to side

Final

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Lockwood installed this slick new washer/overflow bottle before I got it and in the last month the washer bottle slowly leaked out. I thought it was the hose but when I cracked it open to look it was the old washer motor not sealing good in the housing.
I cleaned it up good and added some Indian Head and a touch of RTV and buttoned it back up. Hopefully that will stop the annoying drip.
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Before I put it back in I verified the motor worked with this cool test tool I mentioned earlier.
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Also I added a cap with sticker to the coolant bottle that @ToyotaMatt sent
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Man. Doing the fluids on a lift.

Man.

So, I drained the Tcase and started cussing that Valvoline quick change place again

There was only about a cup of fluid in there. No shavings though so I only used a few choice words.
View attachment 2203479
Then I cracked open the transmission and a bit over a gallon of fluid came out.
View attachment 2203483

Damn. Not good. This means the seal between the transmission and the tcase is out and while driving the tcase fills up the transmission.
I remembered @orangefj45 posting last week he had some used ones. I called him and he got me one on the road today for Saturday delivery. This will be a temporary fix until we dive into Mustard 78 v2 later in the year.
View attachment 2203482
Is the temporary fix going to be a t-case/tranny bypass hose? I ran one of those in my 60 years ago. Worked pretty well.
 
Is the temporary fix going to be a t-case/tranny bypass hose? I ran one of those in my 60 years ago. Worked pretty well.

Yeah, we are thinking a version 2.0 will update that and a little more once it gets too hot to enjoy the 40 in Florida

It’s fine. Not optimal but this truck needs to be in Florida getting driven not here waiting on a tcase rebuild

Wired up the tailgate light. He’s plug and play now

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