1978 FJ40 Stock Restoration – 15 Years Long

[unixman]

Over the last year I collected a few missing items, some of the items I did't even know were supposed to be there. Though I've looked at numerous pictures in numerous threads, I'd appreciate anyone suggesting details I might be missing inside the 40.

One surprise I discovered by accident was the missing throttle position sensor mounted near the accelerator pedal that plugged into the wiring harness.

A couple other items were the light switch bulb itself (never knew that knob was illuminated) and that my carb fan controller was shot. I now have a working carb fan. Very cool I think (pun intended).

The dash looks like it did when I bought it with the replacement of the two labels.

Replaced the rear heater label.

Found a '78 appropriate jack, rods, and handle. Cleaned, primed, and painted per the other threads. Cleaned, greased, and reassembled the jack, but not yet painted.

Found a '78 zippered tool bag and the mounting hardware for the bag and jack. I don't have the tools. I'm content stocking the bag with non-OEM tools for now.

 

[unixman]

Found out there were plastic caps on the spare carrier.

I believe there is also a small bumper to act as a cushion between the carrier and the ambulance door as well as a small plastic cap at the end of the spare handle? I'm also missing one grommet for the unused dash hole.

I have the stickers for the jump seats and the jack, but I've seen no examples of a '78 with the turn-signal decal on the column, a front heater decal, Arakawa body decal, or other label. Anyone see any glaring items I've missed? Just the inside; I haven't started on the top or under the hood. My owner's manual is pretty worn out, too. Does anyone make a reproduction that is stapled and looks original, not the plastic-comb bound one?

 

[wscbill]

I'd appreciate anyone suggesting details I might be missing inside the 40.

Found a '78 zippered tool bag and the mounting hardware for the bag and jack...

Here's a detail for the tool bag latch bracket. Originally, the vertical side of the bracket faced out. Like in this photo from Overton's site.

Shown this way as well in the parts catalog.

 

[unixman]

Here's a detail for the tool bag latch bracket. Originally, the vertical side of the bracket faced out. Like in this photo from Overton's site.

Thanks. I never noticed that.

 

[wscbill]

I believe there is also a small bumper to act as a cushion between the carrier and the ambulance door as well as a small plastic cap at the end of the spare handle?

There is also a rubber piece that fits over the outside edge of the tire carrier lock. NLA from Toyota, but available as rubber edge trim from McMaster. The 3 rubber pieces are in this photo from Overton's site. SOR carries the handle pad, and Overton sells a replica rubber bumper.

 

[DSRTRDR]

blue is faster

 

[unixman]

There is also a rubber piece that fits over the outside edge of the tire carrier lock. NLA from Toyota, but available as rubber edge trim from McMaster. SOR carries the handle pad, and Overton sells a replica rubber bumper.

Ok, I see the pad at SOR and the rubber bumper at LCN. Can you tell me which piece of rubber edge trim here would be the best fit?

 

[wscbill]

Ok, I see the pad at SOR and the rubber bumper at LCN. Can you tell me which piece of rubber edge trim here would be the best fit?

I bought the 8-piece assortment 8510K95 and used the last piece in the list, 1/4" w x 5/16" h, outside measurements. Cut to fit, secured with contact cement on the inside edge to hold it in place.

 

[unixman]

I bought the 8-piece assortment 8510K95 and used the last piece in the list, 1/4" w x 5/16" h, outside measurements.

Great, thanks.

 

[PabloCruise]

Just trying to convey the anticipation of buying a FJ40 and not being able to really enjoy it for 15 YEARS!

I am hooked! Can't wait to read this! After taking 9 years to get a 55 in shape, I can't imagine if I had to wait 15 years to start! Funny how you mention the kids growing. My gauge of time during my Pig resto was looking at pictures of how my little guy grew during the process...

https://forum.ih8mud.com/threads/potm-march-2014-javelina-by-pablo-cruise.798519/

 

[tls3601]

Bill nice detail of below seat hook for toolbag-I believe your orientation of Overton's pic is correct, any other original photo's?? Nice carrier lock pics too!

 

[tls3601]

unix seatbelt solutions quoted me $50-75 to repair each stock retractor mechanism on my stock '78 seatbelts. The seatbelts themselves are in very good condition.

 

[unixman]

unix seatbelt solutions quoted me $50-75 to repair each stock retractor mechanism on my stock '78 seatbelts. The seatbelts themselves are in very good condition.

Good to know, thanks. I'll give them a call. My retractors work, but the webbing is shot. The passenger belt was cut and sewn back together by a PO.

 

[tls3601]

Geez it seems to me that the biggest things I do on my 40 is trying to find parts the PO removed or trying to fix things the PO altered, modified cut or damaged in some way. I can only imagine how great mine would still be today if I was the original owner,, I guess we all imagine this right? What fun we have with these things, huh?

 

[trainrech]

That is what I refer to as P.O.S.

Previous Owner Syndrome.

 

[Landpimp]

dang, your doing a great job! I love the detail

I can't say I have seen a decal for the turn signal before, none of mine have had them.

this is on a unmolested(I am 2nd owner) 82 US spec 40, so while they will work on a 78 they may not have been installed until the latter models.

this clear plastic cover is on my lower driver(left) side rear hinge behind the tire carrier, I am pretty(darn) sure its a stock part, but can't see what point it serves, nothing makes contact with it. (excuse the white wax residue......I really need to get a detail brush)


its similar(but other is clear and harder) to this OEM hood protector that clips to the hard top so you don't get dings when you open the hood all the way(I never use my prop rod)

 

[wscbill]

An interior detail that may be missing is the ambulance door wiring grommet. Part number is 82819-90305. Available from Toyota, CruiserCorps, CruiserParts. Looks like this:

Allows the license bracket wiring to pass through the ambulance door frame.

 

[PabloCruise]

I think I've finally gotten most of her back together. All of the pewter-colored parts are powder coated as are all of the black items including the rear jump seats frames. I did not paint any plastic parts because I think they're fine as they are; a little sun-lightened but acceptable to me. I like the Real Steel tailgate. Not OEM of course, but looks like it belongs there. Heater rebuild was straightforward and I repainted the lettering. Repainted the lettering on the dash knobs too (didn't get the choke yet).

I've addressed numerous little issues on my TO DO list.

FIXED - Windshield wipers (don't park properly - bad ground)
FIXED - Windshield washer inop (bypassed clogged pipe)
FIXED - Dash light inop (bulb out)
FIXED - Heater box light inop (broken solder connections)
FIXED - Light switch bulb inop (burned out)
FIXED - Seatbelt light inop (burned out)
FIXED - License plate lights inop (bad ground)
FIXED - Water temp gauge inop (replaced bad sending unit)
FIXED - Battery won't hold charge (replaced battery)
FIXED - Turn signal switch inop (broken lever)

I still haven't been able to:

1. find the tool kit tool kit band brackets and clip
2. find someone to replace the webbing on my front seat belts
3. repair the carb fan controller relay.

BTW, the pictures are a little washed out. The bezel is not stark white, it's Dover White and a very close match to the original. The Toyota lettering is Almond.
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I like the Real Steel tailgate as well! I have not seen that before.
On my '78, the exhaust comes out on the Passenger side. Are you running a different exhaust configuration than stock?

 

[PabloCruise]

Here are some interior shots. Almost all of the plastic and vinyl in the Cruiser are in very good condition. My front mat is in very good shape as well for the most part. Dash pad is original and in very good shape, too. Looking for a AM/FM radio for the unmolested radio opening. I know FM wasn't an option in 1978 but I'm not building it for display only. Thought about maybe putting in a Toyota 8-Track.

I have no speakers installed and the stock speaker bracket is missing. Have seen only one for sale on eBay but they wanted way too much. Used my sewing machine skills to make a new transfer care shifter boot from naugahyde.

Anyone see any obvious errors anywhere? Hey, you won't hurt my feelings; maybe I'm just looking for more little projects. Next up is the bumper. I've debated buying an aftermarket one for the Warn 8274, but have decided to go stock. Should be in place by the end of the week.

Any recommendations on who can best replace seatbelt webbing?
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That looks great! I thought my '78 (9/77 build date) came w/ AM/FM radio?

Unfortunately it is long gone due to a bad break-up w/ a girl who was bad news. I consider myself lucky if that is all that was lost in the break-up...

 

[unixman]

On my '78, the exhaust comes out on the Passenger side. Are you running a different exhaust configuration than stock?

Yes, it's the only thing under the hood not stock. A PO removed the CA thermo-reactor and replaced it with a CA-legal header. I've debated whether to replace the header with a stock (Federal) manifold and exhaust, but the consensus seems to be that a manifold will eventually crack and I'm best off leaving the header there.