1978 FJ40 Slow build

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Bloomer

SILVER Star
Joined
Dec 25, 2005
Threads
194
Messages
1,544
Location
Just past the middle of nowhere in South Texas
I have always considered a FJ40 as the epitome of Land Cruisers and have dreamed of owning one since before I was 16 (and that was a long time ago). Over the years I have considered buying one and always opted for what seemed more practical for family trips and the somewhat remote area where we live (our trips to the store usually take the better part of the day). So, an 80, 100, and a 200 series that is a family daily driver seemed to always make more sense.

I decided earlier this year to get serious about finding a 40. When I started thinking about what I wanted in a 40, and searching what matched, I QUICKLY found out I could not afford it. Early on, I came across one that a member of the Land Cruiser group I periodically meet with was selling. It was a 1978 dune beige in mostly original condition. It wasn’t perfect but a decent land cruiser. It actually was the first 40 I looked at in my search, and coincidentally the first one I ever drove. At the time, I wasn’t sure it was the right 40 so opted not to buy it. It sold very shortly thereafter, like pretty much the next day.

Over the next several months a couple others came and went for various reasons, they just didn’t work out. I had the opportunity to meet some very nice people and keep in touch with some. I found myself comparing many of the 40’s I looked at to the first 1978 dune beige.

Recently, I was surprised to see the 1978 dune beige pop up for sale again. It was purchased by someone who lived about 3.5 hours away and they started doing some of the work to it that originally caused me hesitation (much of it was minor and just boiled down to me being uneducated). I decided second chances don’t come around often and ended up making an offer the seller accepted. We exchanged signatures on a bill of sale a little over a week ago and I loaded it on a trailer for the drive home. Well, it made it most of the way home on the trailer; I couldn’t wait to drive it so it was unloaded about 60 miles out from the house and it made its way home under its own power.

Over the past week I’ve had some time to have a better look at the 40. A few obvious cosmetic things need to be corrected, mainly the steering wheel, head liner, and a few other odds and ends. There’s no appreciable rust that I can find (some surface) but has some nice patina and a few well placed small dents for character. Emergency brake is not functional and there seems to be an exhaust leak. The smog equipment is all present but pump is frozen up with no belt. I’m suspecting I’ll need to work my way through much of the mechanical components before I really feel comfortable taking it on any trips involving distance. With how simple the 40 is to work on, my head is spinning on where to start. Probably will just baseline fluids then drive it on short runs for awhile to see what needs to be addressed first.

A few pictures of the 1978 dune beige....

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I would be remiss not to say thank you to a few folks who have already directly or indirectly helped me with the 40 and advice along the way in my search.... @cbmontgo @ntsaint @bamabrock @wngrog @jmlockwood @greenbeast @Adog @Indygbd and many more I haven’t listed. Thank you for all the help along the way and to the brain trust that is IH8MUD. Looking forward to fun times with this 40 and many hours searching MUD threads for help!
 
I'll see your 78 and raise you two 77s. Congrats and welcome :flipoff2:
 
A couple interesting documents conveyed with the 40 when purchased. It was purchased new at Brazos Valley Toyota in Bryan, Texas and remained in Texas. The original dealership new car sales inspection report and notes in the owners manual shows it sold in April 1979.

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Fluid baseline started today. Brake fluid flushed and oil change. Also changed the air filter. Full disclosure, my trusted Toyota dealer flushed the brakes for me. They assured me they used DOT 3 and there is only 2 Master Techs that have worked there for 20+ years that will service our vehicles. I’ll do much of the routine PM myself and most mechanical/suspension work, but I don’t do brakes. I can deal with messing something up and a vehicle not starting, but can’t deal with it not stopping (particularly with family along). So, as a matter of principle, I just don’t do brakes.

On the oil change, I’ve done a ton of research and it seems oil weights used vary pretty widely. 15/40 seems really popular but I could not find any with documented zinc levels to feel comfortable going that route. I ended up using Valvoline VR-1 20/50. It has high zinc (~1300 ppm) and comes in both conventional and synthetic. I considered 10/30 but thought that would be too light for an older engine and South Tx climate. I’d be interested to hear anyone’s thoughts on using 20/50......also whether synthetic oil would be a viable option (I used conventional for this oil change).

Cruiser Outfitters has Denso oil filters at a very reasonable price and they also set me up with a new rubber drain plug gasket. I’ve read the drain plug is prone to leak and saw some type of sealant built up around the plug from prior oil changes. I just used a new rubber gasket and wrapped the plug threads with petroleum tape. We’ll see how that works.

Next up will be transmission, transfer case, and diff fluids. Currently sourcing hoses and clamps for the cooling system.

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Had a look at the tools and jack that came with the 40. Was nice to see it retained the jack and rods, complete with nice yellow goodness. No idea if the tool bag is original, but tools are way to shiney to be original to the vehicle (which is ok, just glad to have some). Added the obligatory TLCA sticker.

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Almost not worth mentioning but figured documenting here will help me remember what and when I did various things with the 40. The steering wheel is not original but the seller had ordered one and offered to include it with the sale. It had not arrived when I picked up the 40 so had it shipped to me when it arrived. I started working on replacing it this evening and discovered I will need a puller to remove it from the steering column. So, I reassembled it and will try again another day. Wasn’t all for nothing, the horn was not consistently working so cleaned up the contacts and it seems to be more reliable.

Also purchased a new set of jump seat straps and installed them this evening. Quick win for an improvement.

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Continuing the theme of baselining, changed the front and rear diff oil and transmission oil this weekend. Some of the drain/fill plugs were not easy to free up; used PB blaster and some heat to help. Was not able to find straight 90 wt. so used Lucas conventional 80w/90 and new crush gaskets all around. Ran short on gear oil so will change the oil in transfer case over the next couple days (bought out all the Lucas 80/90 gear oil at the 4 parts stores within 60 miles of me). (2020-10-12 Update, changed transfer case oil last night.)

Sourced new upper and lower radiator hoses from Cruiser Outfitters and stainless hose clamps from City Racer. Next up will be baselining cooling system.

Pics of new sticker for attention.

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“Slow build” was an understatement. Haven’t done much with the 40 as I try to finish up work on the 80. Was fortunate to get a few 40 presents beneath the Christmas tree. Repair manuals, upper dash pad, and hood latches. Installed the hood latches this evening, replacing the black ones with pewter. The dash pad will wait until I am ready to do the headliner and new weather stripping.

Before:
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After:
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Progress on the 80:

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Just over a week ago I drove the 40 into town and noticed on the way back my fuel gauge was showing empty. Was pretty sure I started with almost a full tank and there was no way I ran it empty in the short time I had been driving. Checked fuses and all were good, not to mention only the gas guage seemed to not be reading properly.

Ordered OEM fuel sending unit and gasket from City Racer:

Fuel Sending Unit 83320-60050
Fuel Sending Unit Gasket 83361-20030

Easy installation and fuel gauge is working again!

While changing the sending unit I had a look in the fuel tank and was pleasantly surprised to see it was really clean.
 
Spent some time this weekend doing a little bit of work on the 40. Mainly on the emissions system and replaced the steering wheel.

I had previously purchased a desmog kit but seemed the 40 had most of the emissions system intact, minus the air pump being frozen up, no belt, and no bracket to adjust the tension on the belt. Had been curious how it would run with a functional air pump, and figured I could desmog at anytime if it ran poorly. So, found a used air pump/bracket and was surprised NAPA had a belt hanging in the back store room. Have it all installed. Not sure if I want to think it idles better with the air pump, but sure seems like it does. 😀 I am getting a little bit of a growl from the air pump so we’ll see if it holds up.
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The 40 came with a LeCarra steering wheel, but the PO had an used original steering wheel ordered and included it with the sale. The LeCarra was smaller and comfortable, but just didn’t look the part.
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Finally got around today to finding a steering wheel puller that would work and installed the correct steering wheel.
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Nice progress, looking good 👍
 

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