Builds 1991 FJ75 moving to America (2 Viewers)

[Honger]

I try to forget... but I keep finding more.

 

[c2dfj45]

I try to forget... but I keep finding more.

It will never be gone

 

[Honger]

A little shade tree mechanic work...

And the transmission and transfer case are back in. New clutch, new pressure plate, new throwout bearing, new rear main and pilot bearing, re-sealed the H55F, rebuilt the split case. Some new bushings in the shift linkage as well.

The "while I'm in here" bug has gotten out of control...

 

[Honger]

Taking the dash apart was a necessary step in getting a heater installed. Of course temps are getting warmer here and a heater won't really be needed anytime soon, but while the truck was down for the transfer case and related items, I figured I'd also jump in on the heater.

Calling @AndrewHadji... as promised some photos of the heater assembly box. Granted it's LHD, but I think a lot of it would just be mirrored in terms of orientation. Let me know if there is a specific location/item you want photographed. It's currently in pieces and easy to snap photos of stuff.

When I returned to the States I pinged @joekatana for LHD heater parts and I lucked out... he had an entire assembly. This unit not only houses the heater core but also all of the flaps for varying the spread of air flow through the ducts... floor, front vents, defrost, or mix. My current unit has no heater core and only has options for front vents or defrost. No floor, no mix. As the controls he sent me were for heater only... and my controls are AC only... I'm going to hybrid the two control units and put in a new faceplate.

I took some documentary photos before tearing into it. Here's the heater "diverter". When you engage the heat switch it not only opens the heater valve it also moves this flap to push air through the heater coil.

There are two other flaps within the heater box assembly.

This one opens/closes the path to the floor air...

And this one opens/closes the path to the dash defroster vents...

 

[2fpower]

Love the blitz black. My favorite paint.

 

[Honger]

Love the blitz black. My favorite paint.

I bought a gallon of it. You are the first person I heard about it from. Love it.

 

[Honger]

The core for the heater looked solid, but was quite dirty. The core is brass, so I'm not sure how it got rusty looking. This old core's in/out piping run through swivel joints that have an o-ring inside. I took the core to a radiator shop. They pressured tested, found one of the o-rings leaking, and fixed it. $50, pressure tested and ready to go.

Sadly, the heater housing ended up with a crack in it (I think the box got handled rough in our move). Some JB weld on the inside of the case and fiberglass on the outside and it's serviceable again.

 

[AndrewHadji]

@Honger awesome! Do you remember/ can you figure out which of the selector cables control the vent selector? (Windhsheild defrost, front vents bottom vents etc etc) If you can take a picture of where it is and then a picture of the mechanism itself where the cable connects box side that would be great. If i can get my hand in there rather than pulling that monster out i would be very happy.

 

[Honger]

@Honger awesome! Do you remember/ can you figure out which of the selector cables control the vent selector? (Windhsheild defrost, front vents bottom vents etc etc) If you can take a picture of where it is and then a picture of the mechanism itself where the cable connects box side that would be great. If i can get my hand in there rather than pulling that monster out i would be very happy.

I'm going to be mocking up the controls, cables, and assembly this weekend. I want to confirm functionality prior to re-installing. When I do that I'll capture it with photos, in detail.

Do you have a heat/AC setup? Heat only?

 

[WarDamnEagle]

@Honger awesome! Do you remember/ can you figure out which of the selector cables control the vent selector? (Windhsheild defrost, front vents bottom vents etc etc) If you can take a picture of where it is and then a picture of the mechanism itself where the cable connects box side that would be great. If i can get my hand in there rather than pulling that monster out i would be very happy.

I don't think you will get it connected without at least some disassembly. It's honestly not that hard. I was totally paranoid about taking mine apart but it wasn't that difficult in the end.

 

[AndrewHadji]

I'm going to be mocking up the controls, cables, and assembly this weekend. I want to confirm functionality prior to re-installing. When I do that I'll capture it with photos, in detail.

Do you have a heat/AC setup? Heat only?

Both, and thanks!

 

[AndrewHadji]

I don't think you will get it connected without at least some disassembly. It's honestly not that hard. I was totally paranoid about taking mine apart but it wasn't that difficult in the end.

No worries, and can, just would like to know the scope before i tear into it.

 

[Honger]

While I was in on all of this I removed the second AC... it worked moderately well but took up valuable space and was kind of bodged together. It was pretty clear to us that with tinted windows the main dash AC could easily handle the whole truck.

Loads of fesh-fesh and rotten foam as I took apart the HVAC ducting...

It got worse when I pulled the dash defrost ducting off and got to see inside the mixer box. The defrost/vent switch on my climate controls always felt like it really couldn't go all the way... like something was resisting. And defrost never blew very well, not that I've needed it much. Well, 30 years of "items" falling down the defrost vent into the mixer looks like this...

So loads of cleaning ensued...

 

[Will Van]

While I was in on all of this I removed the second AC... it worked moderately well but took up valuable space and was kind of bodged together. It was pretty clear to us that with tinted windows the main dash AC could easily handle the whole truck.

Loads of fesh-fesh and rotten foam as I took apart the HVAC ducting...

It got worse when I pulled the dash defrost ducting off and got to see inside the mixer box. The defrost/vent switch on my climate controls always felt like it really couldn't go all the way... like something was resisting. And defrost never blew very well, not that I've needed it much. Well, 30 years of "items" falling down the defrost vent into the mixer looks like this...

So loads of cleaning ensued...

Great work! Those nice cleaned up parts are satisfying my OCD.

 

[4Cruisers]

Any valuable old coins in there?

 

[FJBen]

Nice work!

I need to tear mine apart as well. Mine seems to all work(ish) minus the A/C, but thats because I need at least a new compressor. Also everything kind of blows all at the same time, just not as strong depending on where you switch it to.

I have an outside air leak all the time on the passenger side which makes me believe some foam is rotten and not sealing off completely. hasn't been a priority because, well I'm never the passenger

 

[cps432]

Any valuable old coins in there?

A krugerrand or two could pay for a restoration depending on where you live...

 

[RHINO]

There's several of us with Omani Troopies around here... (he lucked out with a 1FZ)

yes for the engine, not so much for the trans,,,, give and take. i wish they woulda left the H55 when they did the 1FZ.

 

[Honger]

No worries, and can, just would like to know the scope before i tear into it.

Hey @AndrewHadji, see this thread. While I had things apart I went a bit overboard. Hope it's helpful.

 

[AndrewHadji]

Hey @AndrewHadji, see this thread. While I had things apart I went a bit overboard. Hope it's helpful.

this is amazeballs, yes what i needed. would it be too much to ask for a short video on the "mix" pic mechanism, you cycling through it manually.