1979 BJ40 Story and Modifications

[AlbertoSD]

The front fenders on the BJ40 will be replaced with new ones. The existing ones had bondo and were cracked in multiple places.

I bought the new fenders from Cool Cruisers:

http://coolfj40.stores.yahoo.net/fronfenfj19t.html

I've read mixed reviews about how well/bad these fit, but I guess time will tell how well they will .

Photos prior to the fender removal...

 

[AlbertoSD]

Fenders out

 

[roma042987]

i have that same model car. looks like some nice work! the pictures from the ride are great i just may have to go next year.

 

[crushers]

you do realize that having a Rover that close to a Cruiser is asking for a bastard child?
them British Rovers are nasty for sneaking over at night and corrupting innocent Japanese land ladies.

enjoying the thread.

 

[Gun Runner 5]

you do realize that having a Rover that close to a Cruiser is asking for a bastard child?
them British Rovers are nasty for sneaking over at night and corrupting innocent Japanese land ladies.

enjoying the thread.

Like most Land Rovers, those Discoveries are probably "sterile" due to in-breeding.

 

[singletrackjunkie]

Looking good Alberto, Thanks for sharing. We'll have to do a trip together when I get mine back

 

[AlbertoSD]

you do realize that having a Rover that close to a Cruiser is asking for a bastard child?
them British Rovers are nasty for sneaking over at night and corrupting innocent Japanese land ladies.

enjoying the thread.

Like most Land Rovers, those Discoveries are probably "sterile" due to in-breeding.

LOL

Looking good Alberto, Thanks for sharing. We'll have to do a trip together when I get mine back

Certainly, Brian!!

 

[AlbertoSD]

This week was kind of slow and not much to report.

I bought a Transfer Case Park brake from TSM and brought it to Jim C. so he can install it when rebuilding the transmission and transfer case

http://www.tsmmfg.com/4066.html

I also cleaned up some previous welds on the frame and power washed the bulkhead to clean it a bit.

 

[crushers]

dog: "get it together so we can go for a ride!!"

 

[Tapage]

let us know ( I mean me ) how this t case e-brake works for ya .. I'm just need more excuses to pull the trigger ..

 

[Gun Runner 5]

dog: "get it together so we can go for a ride!!"

..... and "scratch behind my left ear"

 

[orangefj45]

Finally got a chance to check out your thread Alberto. Nice going bud! It was good to meet you at Rubithon. Bruce is a great tour guide and fun to hang out with.

I'll be sending you another care package shortly.

What's with all the darn Rovers? You guys are gluttons for punishment! Reminds me of an old saying.
"90% of the rovers built are still on the road today"
We usually ad:
"The other 10% actually made it back home"


Keep up the good work!

Georg @ Valley Hybrids

 

[AlbertoSD]

What's with all the darn Rovers? You guys are gluttons for punishment! Reminds me of an old saying.
"90% of the rovers built are still on the road today"
We usually ad:
"The other 10% actually made it back home"
************

Georg @ Valley Hybrids

Thanks, Georg!!!

Regarding the rovers, my friend Chris owns a Rover repair shop and he offered to help me setting up the engine and transmission so it worked out well for me . Once the engine and transmission are set, the BJ40 will return to my house so I can send it for paint and wrap-up all the rest of the truck.

On a similar note, I was working on the BJ40 this weekend, and I sent the photo below to my friends in Venezuela where you can see the 40 in the far left corner.

My friend Fernando (ferportu) said:

"The 40 is probably intimidated by all the Rovers surrounding him"

I responded:

"I think the 40 is probably telling them: Don't worry, I will help you when you break down"

 

[orangefj45]

I bet Chris is stoked that your putting together an RRV.


Rover Recovery Vehicle.

 

[94SRUNNER]

Alberto the 40 has come so far since I last saw it in the garage! The progress is fantastic!

Great talking with you today and I look forward to getting together soon!

 

[Delancy]

I bought a Transfer Case Park brake from TSM

Very nice and perfect timing.

 

[AlbertoSD]

A cool short clip of my buddies trip to San Juan de Manapiare.

http://www.youtube.com/watch?v=P_YOdubDXZI

Hope you guys enjoy the video.

-Alberto

 

[FJ40Jim]

Here's some initial work on the H55. As mentioned earlier, the BJ70 donor was a total rustbucket, so it's no surprise that the tranny was covered in heavy rust.



It was even worse between the AL bellhousing and iron transmission.



But the input spline and pilot bearing snout are in excellent shape.


Here can be seen the heavy rust on the outside, but the decent condition inside and perfect splines for the transfer main drive gear. This is a common wear problem on high mileage H55s, and they are usually very high mileage by the time they get to the USA.



Teardown was fairly uneventful, other than serious rust on some bolts.
Remove top cover and 5th gear housing. Pull rear bearing.



Remove 5th gear. Note that all of the splines and bearing races at rear of trans are good.



Continued....

 

[FJ40Jim]

Next is yank the bearings off the countershaft.
Rear:


Front:


Since we're looking at the front of the trans and the countergear is laying in the bottom, might as well pull the input bearing.
Uh-oh, it does not want to do as it's told.
What happens to inner races that are stuck?
That's right, they get warmed up a little with the OA torch. That explains the scorching in this pic:



And then the input gear is free of the case:


Returning to the rear, the 5th driven gear is still pressed on the shaft. The homemade puller attachment makes quick work of it.



Then pull the rear output bearing:


And lift out the gears, exposing an empty case that needs some serious cleaning inside and out.


Continued...

 

[orangefj45]

Glad you posted these pics Jim. Helps people understand what it takes to rebuild one if these units .......

Good thing for parts washers and bead blasters!


Georg