Builds 1989 FJ62 Refresh - Update Build (1 Viewer)

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Beams37 said:
During the process, I replaced all of the screws that hold the frames that hold the light housings in the truck. If you ever do this or replace your lights, these will be a nightmare. Replaced with stainless screws, so hoping they will hold up for another 35 years.

IMG_2867.jpg
Click to expand...
HA. I just had the same experience while "replacing a high beam bulb real quick". She's sitting with the front end ripped out waiting on replacement hardware and grommets.

Great build - would love to see it in person sometime!
 
IDKGiveItAShot said:
HA. I just had the same experience while "replacing a high beam bulb real quick". She's sitting with the front end ripped out waiting on replacement hardware and grommets.

Great build - would love to see it in person sometime!
Click to expand...
Yeah. I also ordered a bunch of replacement grommets, but was able to get it back together for the time being.
 
Anyone know what this is? Is it important? If so, any clue on part#?

Sits on passenger side wheel well, between washer reservoir and air cleaner.

IMG_2936.jpg
 
Looks like a fried aftermarket circuit breaker notice both wires on the same terminal. Trace the wiring down and see what it hooked to or not hooked to and repair it the correct way if it's even needed.
 
tmxmotorsports said:
Looks like a fried aftermarket circuit breaker notice both wires on the same terminal. Trace the wiring down and see what it hooked to or not hooked to and repair it the correct way if it's even needed.
Click to expand...

Sounds good. I'll track it down tomorrow.
 
Had a productive day. Started cleaning my engine bay and removed some wiring that had been partially removed during the desmog (I assume). Also got a new rear door handle installed. The old one would stick open and was a PIA. Now, I want to replace them all with nice shiny new handles. LOL

The big task today, we removing the cruise control from the system. It was a mess of wiring running all over the truck. It was one of those things where you wonder if everything would work afterwards. Luckily ... all good !!
 
Started the alternator replacement project. I'm hoping it will fix my electrical gremlins. instead of going OEM, I picked up a high output one from Power Bastards (I just couldn't resist the name). All I can say is that getting the AC idler pulley loose is a freaking nightmare. So, I will finish that up this weekend along with new belts. I'll also be replacing the battery and ground cables with the upgraded set from @Fourrunner . Pics coming this weekend.
 
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Was hoping to post cool pics of my alternator installed, but broke the only bolt left connecting the adjuster arm to the bracket that connects to the block. Luckily, it's NLA and I don't currently have a back up plan.

So, my current plan is to take it off, hope it doesn't F up the gasket for the water pump (these bolts appear to be part of what's holding the water pump), and pray to go I can drill and tap the holes. Should be an awesome Saturday. LOL

IMG_2947.jpg
 
So, here's the current state of affairs. I got a lot done, but nothing finished.

I was able to get the bracket with the broken screws fixed and painted. A buddy of mine was able to weld on a bolt and we were able to get the broken bolts out. As part of this process, I cleaned up all the threads, applied some anti-seize, and got new hardware (where applicable) to make sure there aren't any issues in the future. When I removed the bracket, I was getting a little dripping (maybe a few ounces over 24 hours) from the water pump gasket. It appears the dripping has stopped now that everything is reinstalled and torqued to spec. I also got the Power Bastards (I just love the name) alternator mounted. The one I took off was a re-manufactured unit (no clue on age). Here's what that looks like at the moment.

IMG_2960.jpg


I also got the @Fourrunner battery cables all installed. Probably would have been easier in warm weather, but they are all in and are beastly. I left everything unhooked for 2 reasons. 1: I have new stainless trays incoming. 2: My tray is basically non-existent. So, that should be complete as soon as the new trays arrive.

Cables that are visible. You can see the quality.
IMG_2961.jpg


What's left of my current battery tray. LOL
IMG_2962.jpg
 
Beams37 said:
So, here's the current state of affairs. I got a lot done, but nothing finished.

I was able to get the bracket with the broken screws fixed and painted. A buddy of mine was able to weld on a bolt and we were able to get the broken bolts out. As part of this process, I cleaned up all the threads, applied some anti-seize, and got new hardware (where applicable) to make sure there aren't any issues in the future. When I removed the bracket, I was getting a little dripping (maybe a few ounces over 24 hours) from the water pump gasket. It appears the dripping has stopped now that everything is reinstalled and torqued to spec. I also got the Power Bastards (I just love the name) alternator mounted. The one I took off was a re-manufactured unit (no clue on age). Here's what that looks like at the moment.

View attachment 3808964

I also got the @Fourrunner battery cables all installed. Probably would have been easier in warm weather, but they are all in and are beastly. I left everything unhooked for 2 reasons. 1: I have new stainless trays incoming. 2: My tray is basically non-existent. So, that should be complete as soon as the new trays arrive.

Cables that are visible. You can see the quality.
View attachment 3808968

What's left of my current battery tray. LOL
View attachment 3808970
Click to expand...
These cables and the stainless steel tray were one of my first projects. The cables really made a difference on cranking/starting and weird electrical fluctuations that I can only attribute to bad grounding. It all went away after that. My battery tray was in similar condition, basically peeled it away.
 
Tiamat said:
These cables and the stainless steel tray were one of my first projects. The cables really made a difference on cranking/starting and weird electrical fluctuations that I can only attribute to bad grounding. It all went away after that. My battery tray was in similar condition, basically peeled it away.
Click to expand...
Yeah. I generally equate all electrical gremlins to bad grounds, bad relays, or a bad alternator in these old trucks. I may be wrong, but it's how I see it.

Very excited about the trays. Going to install one on each side. I'm not a huge overlander, but want the ability in the future to take longer camping trips and run all the electrical I want (fridge, inverter, etc.).
 
No more drippage. So, I'm going to put on belts and put the system under pressure tonight to see what happens. No point in moving forward until I know it's gonna hold.
 
Tonight, I put on one of the belts (alternator to water pump to crank) just so I could get it running and up to temp. Got up to temp and ran for about a half hour. No issues and no leaks. Going to let is sit overnight to see if anything changes, but seems like I may have avoided a catastrophe.

One of the reasons I only put on one belt was that I have new belts coming Thursday and I didn't want to do all three belts twice. The other reason is I was having trouble with this idler pulley. It seems that the bolts moves freely, but the pulley doesn't go anywhere. Can someone confirm that this is in fact supposed to move? Not my picture, but it is the pulley I'm referring to.
Desmog Belt Picture (1).jpeg


Next question: I was putting the alternator back together. It seems like the nut (circled in blue) should have treads that connect it to the bolt on the front of the bracket, but it doesn't. Is it supposed to "float" or should it have threads that match the bolt on the front?

IMG_2963.jpg
 
On a VERY positive note, the new alternator is charging right at 14V and my stereo cutting in and out has completely stopped. So, I'm extremely excited to have tunes again!
 
Yes, that is the AC idler. Loosen the center bolt and move it with the adjusting bolt.

The bracket on the alternator just floats on there! Loosen the bolt on the front, use the adjuster bolt to tension the belt, then tighten bolt on front.
and the bottom bolt.
 
ThorH said:
Yes, that is the AC idler. Loosen the center bolt and move it with the adjusting bolt.

The bracket on the alternator just floats on there! Loosen the bolt on the front, use the adjuster bolt to tension the belt, then tighten bolt on front.
and the bottom bolt.
Click to expand...
Ok. I think I circled the wrong idler. Lol

The on for the AC moved fine after I loosened the center bolt. The other idler (for power steering) does not move when the adjustment bolt is moved. Tried loosening the central bolt, but it just moves with the bolt.
 
Ok. Any ideas on this pulley? Adjustment bolt moves in and out, but the pulley is not moving horizontally as the bolt turns. Bolt on the front doesn't seem to be holding anything in. Thoughts? Ideas?

Desmog Belt Picture (2).jpeg
 
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