Builds 1984 Desert 40 - Teardown and Rebuild

[jgeoffr]

Steering rehab continues. Tore down and resealed the power steering gearbox.

Gearbox power washed.

Blasted.

Resealed, painted and replated hardware installed.

Steering components installed. New 555 tie rod ends, rebuilt center arm, rebuilt Pittman arm.

-Geoff

 

[jgeoffr]

Brake line fun. Started mocking up the new lines. Tried out the 96910-32305 lines from the knuckle to the axle. As you can see it was too tight of a fit.

Too much strain on the line.

For reference, here is the same line on another truck.

It was clear that the tab was causing some problems. Could have bent it up, but decided to try the 96940-32605 hose that goes from the frame to the axle.

Fit much nicer and gave me the length I needed. At full lock the hose did not touch the shock. Only issue is that the female end of the hose is not the right shape (it has a hexagon protrusion instead of being round). I have ordered two more of these hoses and I will be machining it back to a round neck to fit the axle. Two steps forward, one step back.

-Geoff

 

[jgeoffr]

A fist for me was bending hard brake lines. I found it to be a bit intimidating at first, but not bad once you get the technique down.

First hard line bent and mocked in to check clearances.

Had to put in some of the fuel lines to make sure brake lines would clear.

A couple of close-ups.

Another.

-Geoff

 

[Bear]

Looks good, Geoff.

 

[jgeoffr]

Man, been way too long since updating...

Lots of work on the body. Underside was primed, coated and painted.

-Geoff

 

[jgeoffr]

H55 speed rebuild. Spoiler, I'm pulling it back out to put back in the H41. With the OME lift and the 5th gear, the driveshaft angle becomes too extreme. Gonna put the H55 in my new 82 FJ45 troopy!

-Geoff

 

[jgeoffr]

More of the H55 rebuild and one pic of the split case rebuilt. All new seals and bearings as well as synchro. Replaced worn gears, shift forks, and shafts as well. Can't find pics of split case rebuild right now.

-Geoff

 

[jgeoffr]

Roof drip rail and hardtop repair.

-Geoff

 

[jgeoffr]

More fiberglass repair.

-Geoff

 

[jgeoffr]

Shaved the mirrors off the doors. Going to go with windshield hinge arms.

-Geoff

 

[jgeoffr]

Applied glass microspheres on the inside and outside of the firewall for insulation.

-Geoff

 

[jgeoffr]

Engine, transmission and transfer case installed on frame.

-Geoff

 

[jgeoffr]

Rear brake shoes and hardware in.

-Geoff

 

[jgeoffr]

Replacing worn exhaust and fabricating bracket and pipe. Having to fix PO's welding on of exhaust.

-Geoff

 

[jgeoffr]

More exhaust shots including the replacement muffler.

-Geoff

 

[jgeoffr]

Finish work on exhaust.

-Geoff

 

[jgeoffr]

Paint on. Toyota 033 in PPG Global Refinish direct gloss. Color is yellow due to interior lights.

-Geoff

 

[Michael B]

Nice progress Geoff! I wondered where you had been.

 

[jgeoffr]

More paint and body mounts going on. Polybushings and new OE hardware with exception of the 4 hockey puck for the rear bed. The polybushings don't have the metal retaining plate.

-Geoff

 

[jgeoffr]

Nice progress Geoff! I wondered where you had been.

Thanks! Had switched over to Instagram and just failed to keep up here. Trying to catch up on the progress.

Still a lot of starts and stops. Small part issues can lead to a 3 to 4 week delay...

-Geoff