Builds 1978 US Market FJ40 Factory Restoration

dmaddox · Aug 15, 2020

Now, for the hi/low selector shaft and fork.

More cleaning and polishing, then a new rubber o-ring goes on:

Another spring and bearing go inside this, along with a cotter pin:

Front drive selector clutch:

Preparing for the front drive cone. IMPORTANT STEP - make sure you install the new bearing race into the back of the cone, that will ride against the exposed bearing you see here. Another FSM catch!

dmaddox · Aug 15, 2020

Red (pink) FIPG, new gasket, setting in place:

Blue thread locker, along with some new hardware:

Front drive assembly installed:

Back to the SST curtain rod to re-torque front pinion nut. (I set to 120ft/lbs.):

Now, while the left over frame paint is drying on the speedometer housing, I'll clean up the inside and prepare. New orings:

dmaddox · Aug 15, 2020

Housing dry, with the new seal set in place:

New felt for the speedometer end, and gasket:

Here is where I will add another point of frustration - as I am sure you have experienced, if you built one of these.

There is a step to "seat the rear bearing race". Well, at this point it is too late. With the speedometer housing installed with the same shims as before, you'll not be able to barely turn the gears, it will be so tight.

I had to install an old pinion nut onto the back of the output shaft and beat on it with a rubber mallet until it spun freely. Any tips or ideas someone may have to help others on this whole output shaft spacing/etc.. would be appreciated.

Once that was done. Sigh of relief.

Turned out pretty snappy, I thought anyway.

Oh, check this out. Over the last year, I have been watching ebay and the classifieds on 'mud to complete the 1978 manuals.

I think I have them all now, after finding the wiring diagram guides. I am a nerd for this kind of stuff. However, it IS pretty cool to have them on-hand.

dmaddox · Aug 15, 2020

Again, while the rear e-brake backing plate and drum (I shot these with a gloss black, to help with cleanup) are drying, I decided to dive into rebuilding the bits:

Ugh, rusty and gross! Before and after:

Assembling the "Terrain Tamer". E-Brake shoes. Not sure how an e-brake tames the terrain, but ok.

FSM shows this - which is a fairly straight-forward install:

dmaddox · Aug 15, 2020

More SST Curtain Rod, and the rear nut to 120ft/lbs. Then, my pull-scale (which by the way, Kurt @cruiseroutfit sent me a pink one?) to measure the resistance of the e-brake per the FSM.

Top cover gasket for the hi/low lever:

Complete, just need the shift linkage and will be ready to install on the back of the transmission.

Thank you for reading along.

Kicking my feet up. Have a great weekend mudders.

Curtice · Aug 15, 2020

wow!! Awesome! I know what I’m gonna be using when I get to my transfer case (once done with my transmission). Great info.

That two part spray stuff is cool. I had bad luck with the Eastwood 2k paint, but when I used the spray can two part version, it was awesome. I’ll probably copy you here.

And I laughed at the pink scale haha

ToyotaMatt · Aug 15, 2020

dmaddox said:
Housing dry, with the new seal set in place:

View attachment 2405633

New felt for the speedometer end, and gasket:

View attachment 2405634

Here is where I will add another point of frustration - as I am sure you have experienced, if you built one of these.

There is a step to "seat the rear bearing race". Well, at this point it is too late. With the speedometer housing installed with the same shims as before, you'll not be able to barely turn the gears, it will be so tight.

I had to install an old pinion nut onto the back of the output shaft and beat on it with a rubber mallet until it spun freely. Any tips or ideas someone may have to help others on this whole output shaft spacing/etc.. would be appreciated.

Once that was done. Sigh of relief.

View attachment 2405635

Turned out pretty snappy, I thought anyway.

View attachment 2405636

Oh, check this out. Over the last year, I have been watching ebay and the classifieds on 'mud to complete the 1978 manuals.

I think I have them all now, after finding the wiring diagram guides. I am a nerd for this kind of stuff. However, it IS pretty cool to have them on-hand.

View attachment 2405637

Great TECH all above Dallas !

the 2 part is amazing

i only noticed 1 minor ..........well you know " thing "

you are missing this .......

it's a must have for your current build state thus far

otherwise your 1978 Print Media Library is MOST impressive !

dmaddox · Aug 16, 2020

Good call - it is in the mail. I should have it this week. (The supplement) I forgot I found one and it was still on the way.

JDNs78FJ40 · Aug 16, 2020

Curtice said:
Lol you made me feel so much better when you said "I am into this thing $40K" . Right there with you...

It seems there are a lot of us in this same boat. Keep the madness going

dmaddox · Aug 17, 2020

Bushing / spacer question.

I still have everything apart, nothing staked it n place yet and I have two spacers. Yeah....a "parts left over" situation.

The spacer and washer on the right - I believe (98% certain) go on the back of the t-case under that cone. The bushing/spacer on the left? Does it go in the back of the transmission? That's the only place I can see it might go?

The FSM is not clear. Thoughts?

dmaddox · Aug 17, 2020

There’s also this seal, which fits perfectly into the front of the tcase where the trans shaft comes in, but the FSM has very little of anything on the connection of the two.

dmaddox · Aug 17, 2020

Found where the seal goes - here Transfer Case to Transmission Leak?

Now I just need to solve for the spacer on the left, as shown above.

dmaddox · Aug 17, 2020

...and this appears to be the spacer. I guess I just need to use the search function and dig a little more.

Transmission Output shaft spacer wear

Hi all, I separated my transmission and transfercase last night, and took a look at the short spacer that rides on the output shaft of the transmission. What I found was a bit concerning... This is the spacer in question: When I pulled it out, there was a degree of surface rust. Is this...

forum.ih8mud.com

Apologies! In my defense, you know the feeling of installing a transmission, and then you see an extra part sitting there.

dmaddox · Aug 25, 2020

I have (finally) finished the transfer and trans install. Aside from a few items I painted (breather/vent and the long bolts that secure the transfer case to the trans) gold - yes, that's right, I have used all new cad hardware and cleaned things up best I could. I don't have a shop near me that plates stuff, although I am sure there's one around.

Here you can see I used nicopp brake line as well, bending by hand:

bmoonhajjar · Aug 25, 2020

Damn you some some nice work!!

dmaddox · Aug 25, 2020

Onto the front axle / knuckles. I didn't take many photos of the disassembly, pretty common stuff. However, when taking stuff apart, it looks like someone was in there in the last 5K miles or so, but decided to reuse worn bearings and seals.

Overall, with a little polishing, the axle in general and the knuckles are in good shape.

I used to have the luxury of a fully outfitted 60x100 family shop. Now, trying to do a top notch restoration is a 1 car garage that is falling apart (literally).

More disassembly and cleaning.

The backing plates were mashed in several areas and because I am working alone with limited tools, the axle at one point, slid off the hand-cart and onto the ground. So, I am working here on straightening them.

dmaddox · Aug 25, 2020

As mentioned, trying to lift and haul (soliciting your sympathy here, guys - ha!) an axle by myself, pic just before i lost control and bent a dust shield (now repaired):