1991 FJ80 - Long Overdue Build and Maintenance (1 Viewer)

[oldboy]

Hey all. I have been lurking forever and learning so much. Really appreciate this forum and all the posts.
I figured I should probably help contribute for all the others committed to their FJ80 and 3FE.

I will probably need to do some corrections as I go. It has been a while on some of these things.

Around 2008 I really wanted to buy a 100 series while I was in the service but the now ex pushed for a Sequoia. Had a great 2003 Sequoia until about the end of 2012 when the ex totaled it. Insurance only reimbursed the remaining loan amount unfortunately. At the time I was going to school full time living off the GI Bill. I took out a small student loan and picked up a clean 1998 RX300 but luckily I lost that in my divorce... and then was able to finally get a land cruiser.
2013 I asked for more student loan money and found my 1991 Land Cruiser in Portland. A little dirty but ran well and I think it had around 150k miles all for $5k.
Daily driven since.


Here is a photo from I think 2013/14 (will need to dig a bit more to find some of the first day photos)

It all went well until 2014.
I went to work in downtown Portland, OR. Parked in my narrow parking garage.
When I got off work, I could not get the thing to start.
Had to make about 10 runs to parts stores/Toyota and replaced the following over several days:
-New EFI relay, like the 3rd one at this point. Kept a spare in the car even.
-Fuel Pump
-Fuel Filter
-Spark Plugs
-Wires
-Distributor cap and spiny boy

With some help was able to get it started and somehow out of the garage so it could be towed. Took it over to a Toyota in Vancouver, WA. They were all over the place. I had asked them to tell me before they tore into anything. After about 2-3 weeks without any new information I finally asked for my car back (Back then that was a long time to wait). They informed me that they had ripped my entire dash out. Unfortunately losing screws and breaking several retaining parts of the dash in the process. Also, I now have some short that persists today causing my lights to brighten when I step on the gas or roll the windows up/down..

Got it over to a local mechanic that was recommend and within 3 hours, they identified that the issue with the connector for the EFI relay. They manually bent slightly and added some dialectic grease and its been rock solid since.
I was pretty broke during this time but was able to get out on several light off road trips and to many hiking spots.

2015, I sold everything I owned that didn't fit in the 80 and moved to CO.
~2016 "Upgraded" to KO2 31x10.50R15LT - honestly they have been great and are lasting forever. Such a wild difference in the snow! I really regret not getting 33" though more for the looks as these have been great.
Added full weathertech mats

some time around 2017

2020 Moved again to VA.
Still daily, but man is it leaking.
In 2020 I was finally in a position that I could actually buy something with like ABS or airbags.
I looked a lot.
2021 was still looking, but now the rona had me working from home and even less pressure to actually find something.
2022 still looking. Maybe a Tacoma? Maybe a 4runner?
2023 Nah
I just like my slow 80. Decided to keep it.
Sent if over to Ironpig to help me get it pointed in the right direction.

Did the following:
Brakes
-New Parking Brake wire RH/LH
-Brake Shoe Kit
-Caliper RH/LH
-Pads
-resurfaced rotors
Knuckle Rebuild
-Industrial Moly EP Grease
-80W90 Gear Oil
-Wheel Bearing Kit
-Tie Rod Ends
-Spindle Sub-Assembly, Steering Knuckle - Fuji
-Longfield FJ80 30-spline gun drilled super set (this might be wrong as I think it was the long 24 spline, need to check more later)
Suspension & Driveshaft
-OME standard load kit (2851/2860 spring and 63018/63020 shock)
-CA77B Caster
-SD24 Damper
-Toyota Drive Shaft
Leaks
-New radiator (will need to find the name later but they kept my old one for science since it weighed like 3x more than it should)
-3fe Timing cover gasket set
-coolant flush
-speedy sleeve
Fluids
-Mobil1 Dexron/Mercon Transmission Fluid
-10W30 Motor Oil
-Oil Filter
-Rear Diff fill/gasket
-a few hose clamps

I also replaced the original frayed drivers seatbelt, so nice!

2024
-TNT automotive added tint
Literally like a week later my driver side front window just fell off, scratching up the nice new tint!
-Wellvisor Window Visors added.
-New Toyota Window Runs!! (68141-60010 FR, 68151-60010 FL, 68142-60011 RR, 68152-60011 LR)
-Switchdoctor master switches, I know I should have gone toyota
-Delta VS Gas Cap Holder (Why the hell did no one tell me this existed and where was mine!?)
-Toyota Windshield washer nozzle (Someone please suggest something better!)
-Toyota Interior door handle covers
-SolveFunction Shaky Mirror Fix, was using silicone. Ok so pro tip. Do not tighten them. I am sure somewhere it says not to do this. But I broke my glass. I tried to install glass from ebay, did a super good job cleaning it all up and could not get it over the lip. broke new glass.
-SCITOO L&R Mirror, the whole thing. they are black and I don't care. Amazon special. Honestly working great and the motors actually work now too.
-Toyota Rear Hatch Weather Seal
-Healights - Philips 9011 HiR x4
-All the vacuum lines I could find in 90999-92002. Also I noticed afterwards that maybe I was supposed to use 90999-92003*?? Anyone know the difference as the "2*" seemed to work well.

 

[oldboy]

Currently working on a few things, like ordering a bunch of small parts Ill share later.
Also, struggling with a few items.

Does anyone know the part number for:
-Coolant Reservoir cap
-Tcase weaved ground that is holding on for its life
-whatever hangers/mounts/soft things I need for exhaust mounting? One is broken and its basically touching the driveshaft...

I am also trying to figure out what is happening with a leak. I think its coolant only (though honestly there is some small oil leak too I am less worried about. Burning maybe .5 quart every 2 months.
But I have added 2 gallons of coolant over the last few months. I want to pick up that reservoir cap as that is the last thing not new around that area and there is calcium build up or something in it.
Leak shots, sorry its dark:

lots of fluid on this... plate I don't know the name of. Looks like coolant.

Some drippy buildup on that bolt in the center

puddle

Looks like coolant dripping around this general area

...

 

[oldboy]

continued

new rad, new toyota cap (small leak evident, cap was replaced after)

Note some residue. Also under reservoir only small amount of moisture.

Looking dry

 

[oldboy]

Continued

 

[oldboy]

Looking at picking up a few small things.
I need the plastic bolt holder things for the rear inside steps. I think the part number is 90467-04017-E1(or E0). They both seem to be the same color but need to validate or buy both.
Going to start collecting bulbs for dash... If anyone has a solid write up on this for the 1991.. that would be nice.
I think the part numbers I need are:
green either bulb or nipple cover - 90072-02006 x1
bulbs 90072-02005 x8
Dash screws. I am actually not sure if these are all the same. Seems like people just grab one and match it as hardware store but I was going to pick up 93568-55014 x 5
And again, may buy some of the "92003" vacuum lines but have not figured out if that is needed.

 

[jeffro109]

The best advice I have is to clean it all off very well (degreaser, car wash, etc.) and see where it starts leaking again. This is a big mess, and it is hard to guess what the root cause is.

 

[Malleus]

Hey all. I have been lurking forever and learning so much. Really appreciate this forum and all the posts.
I figured I should probably help contribute for all the others committed to their FJ80 and 3FE.

I will probably need to do some corrections as I go. It has been a while on some of these things.

Around 2008 I really wanted to buy a 100 series while I was in the service but the now ex pushed for a Sequoia. Had a great 2003 Sequoia until about the end of 2012 when the ex totaled it. Insurance only reimbursed the remaining loan amount unfortunately. At the time I was going to school full time living off the GI Bill. I took out a small student loan and picked up a clean 1998 RX300 but luckily I lost that in my divorce... and then was able to finally get a land cruiser.
2013 I asked for more student loan money and found my 1991 Land Cruiser in Portland. A little dirty but ran well and I think it had around 150k miles all for $5k.
Daily driven since.


Here is a photo from I think 2013/14 (will need to dig a bit more to find some of the first day photos)
View attachment 3751457
It all went well until 2014.
I went to work in downtown Portland, OR. Parked in my narrow parking garage.
When I got off work, I could not get the thing to start.
Had to make about 10 runs to parts stores/Toyota and replaced the following over several days:
-New EFI relay, like the 3rd one at this point. Kept a spare in the car even.
-Fuel Pump
-Fuel Filter
-Spark Plugs
-Wires
-Distributor cap and spiny boy

With some help was able to get it started and somehow out of the garage so it could be towed. Took it over to a Toyota in Vancouver, WA. They were all over the place. I had asked them to tell me before they tore into anything. After about 2-3 weeks without any new information I finally asked for my car back (Back then that was a long time to wait). They informed me that they had ripped my entire dash out. Unfortunately losing screws and breaking several retaining parts of the dash in the process. Also, I now have some short that persists today causing my lights to brighten when I step on the gas or roll the windows up/down..

Got it over to a local mechanic that was recommend and within 3 hours, they identified that the issue with the connector for the EFI relay. They manually bent slightly and added some dialectic grease and its been rock solid since.
I was pretty broke during this time but was able to get out on several light off road trips and to many hiking spots.

2015, I sold everything I owned that didn't fit in the 80 and moved to CO.
~2016 "Upgraded" to KO2 31x10.50R15LT - honestly they have been great and are lasting forever. Such a wild difference in the snow! I really regret not getting 33" though more for the looks as these have been great.
Added full weathertech mats

some time around 2017
View attachment 3751491

2020 Moved again to VA.
Still daily, but man is it leaking.
In 2020 I was finally in a position that I could actually buy something with like ABS or airbags.
I looked a lot.
2021 was still looking, but now the rona had me working from home and even less pressure to actually find something.
2022 still looking. Maybe a Tacoma? Maybe a 4runner?
2023 Nah
I just like my slow 80. Decided to keep it.
Sent if over to Ironpig to help me get it pointed in the right direction.

Did the following:
Brakes
-New Parking Brake wire RH/LH
-Brake Shoe Kit
-Caliper RH/LH
-Pads
-resurfaced rotors
Knuckle Rebuild
-Industrial Moly EP Grease
-80W90 Gear Oil
-Wheel Bearing Kit
-Tie Rod Ends
-Spindle Sub-Assembly, Steering Knuckle - Fuji
-Longfield FJ80 30-spline gun drilled super set (this might be wrong as I think it was the long 24 spline, need to check more later)
Suspension & Driveshaft
-OME standard load kit (2851/2860 spring and 63018/63020 shock)
-CA77B Caster
-SD24 Damper
-Toyota Drive Shaft
Leaks
-New radiator (will need to find the name later but they kept my old one for science since it weighed like 3x more than it should)
-3fe Timing cover gasket set
-coolant flush
-speedy sleeve
Fluids
-Mobil1 Dexron/Mercon Transmission Fluid
-10W30 Motor Oil
-Oil Filter
-Rear Diff fill/gasket
-a few hose clamps

I also replaced the original frayed drivers seatbelt, so nice!

2024
-TNT automotive added tint
Literally like a week later my driver side front window just fell off, scratching up the nice new tint!
-Wellvisor Window Visors added.
-New Toyota Window Runs!! (68141-60010 FR, 68151-60010 FL, 68142-60011 RR, 68152-60011 LR)
-Switchdoctor master switches, I know I should have gone toyota
-Delta VS Gas Cap Holder (Why the hell did no one tell me this existed and where was mine!?)
-Toyota Windshield washer nozzle (Someone please suggest something better!)
-Toyota Interior door handle covers
-SolveFunction Shaky Mirror Fix, was using silicone. Ok so pro tip. Do not tighten them. I am sure somewhere it says not to do this. But I broke my glass. I tried to install glass from ebay, did a super good job cleaning it all up and could not get it over the lip. broke new glass.
-SCITOO L&R Mirror, the whole thing. they are black and I don't care. Amazon special. Honestly working great and the motors actually work now too.
-Toyota Rear Hatch Weather Seal
-Healights - Philips 9011 HiR x4
-All the vacuum lines I could find in 90999-92002. Also I noticed afterwards that maybe I was supposed to use 90999-92003*?? Anyone know the difference as the "2*" seemed to work well.

I always buy the -92004 (one yard-ish).

 

[Malleus]

Looking at picking up a few small things.
I need the plastic bolt holder things for the rear inside steps. I think the part number is 90467-04017-E1(or E0). They both seem to be the same color but need to validate or buy both.
Going to start collecting bulbs for dash... If anyone has a solid write up on this for the 1991.. that would be nice.
I think the part numbers I need are:
green either bulb or nipple cover - 90072-02006 x1
bulbs 90072-02005 x8
Dash screws. I am actually not sure if these are all the same. Seems like people just grab one and match it as hardware store but I was going to pick up 93568-55014 x 5
And again, may buy some of the "92003" vacuum lines but have not figured out if that is needed.

The -02006 (gren cap) bulbs are the same as the -02005, just without the green cap on them. The bulbs (actually the lamp assembly -bulb and socket; you can't remove the bulb) come with the cap on them, or you can use a sharpie.
Or you can go LED (post #13)
Dash screws are a joy:

This is from the 1995 serivce manual and EPC; you'll need to check this against the 1991 service manual (It's in the Reousces section) and EPC (use PartSouq, if you don't have any other, better, tool, and you VIN).

I have a box of these; I pick them up every time I'm in a salvage yard. They are common 90's vintage Toyota interior screws; not specific to a Land Cruiser.

 

[Malleus]

How close are you to Bealeton?

If you're close enough, and I'd do this if it was me, I'd make a road trip and get a professional opinion. It'll be worth the drive. Bring beer.

 

[oldboy]

The best advice I have is to clean it all off very well (degreaser, car wash, etc.) and see where it starts leaking again. This is a big mess, and it is hard to guess what the root cause is.

Hey now that's premium patina and rust protection right there. Hard to tell but I actually did start this(top side). Have any recommendations on products?

View attachment 3752448
I always buy the -92004 (one yard-ish).

Oh s***, see I just bought like 9x 92002... The parts person over here is nice but not super helpful and had no idea what I meant when I asked if they had a spool or larger amount. Good tip!!

Thanks for the dash and screw part#!

How close are you to Bealeton?
View attachment 3752463
If you're close enough, and I'd do this if it was me, I'd make a road trip and get a professional opinion. It'll be worth the drive. Bring beer.

I am about an hour away from OTRAMM and LC heaven and Ironpig. I have been working with Lance at Ironpig who has been great and is willing to take extra time to answer a lot of questions. Have you used OTRAMM? I know people like them. LC Heaven seemed to be having issues last I checked.

I feel like this is some hose I can do myself. Just have not found it yet. All oil/tranny fluids look clean as far as I can tell so I am not in a need situation yet.

 

[Malleus]

I have no personal experience with Ryan, but watching him work, he's at least as competent as any mechanic I'd ever want to work on my trucks. I'd have no reservation about giving him a try. I suggested dropping in on him, because, since he sees so many trucks, he'd should be able to give you a quick assessment of your potential future work, and give you an idea on where to start, with PM in mind.

Lance seems to be a good guy, too. I've spoken with him, and threatened to buy one of his 40s, once upon a time, but I don't have any personal experience with him, either.

I can't comment on LCH.

 

[oldboy]

I have no personal experience with Ryan, but watching him work, he's at least as competent as any mechanic I'd ever want to work on my trucks. I'd have no reservation about giving him a try. I suggested dropping in on him, because, since he sees so many trucks, he'd should be able to give you a quick assessment of your potential future work, and give you an idea on where to start, with PM in mind.

Lance seems to be a good guy, too. I've spoken with him, and threatened to buy one of his 40s, once upon a time, but I don't have any personal experience with him, either.

I can't comment on LCH.

The trucks at iron pig are seriously impressive!

 

[Marco Lau]

you can order the rubber seal under the coolant reservoir cap. That was what i did.

 

[oldboy]

Went to change out my belts today, and come to find that the Alternator adjustment bolt is bent. Not sure if this was me or a shop visit. Maybe I am looking at the wrong diagrams for part numbers but some seem partially incomplete. I want to just buy new adj bolt and locking bolt and the block.
-Locking Bolt: 90109-08205
-Locking Bolt Washer: 90201-08135
-Block (the two bolts meet at): 16381C ???
-Locking Bolt end part: 90445-11054
-Adjustment Bolt: 90119-08626 (But I also found a 91651-60820(3) )

Found this image that looks to be correct though its too tight to take a photo(for me the long one is bent up and I assume it will need to be cut out)

Probably going to take this in to a friends shop, my brackets for my exhaust are old and one broke, so need to get it to stop being millimeters away from the drive shaft. And still looking for the coolant leak.

Currently, really debating refinishing the wheels and continuing to limit my tire options or getting something else. I was kind of shocked how nice the sequoia 5 spokes for like 2003 looked on the 80. I am also always a fan of a traditional steel off road wheels. Open to what you have found success on as it always gives me a headache figuring out what is actually going to fit. I am not interested in spacers.

Additionally, picked up a bunch of random parts thanks to all of you. Soon my dash will be secure!

Note for others looking to replace the step plate clip 90467-04017-E1 this is the brown one (oak). Additionally I found this on mud with a file, though the link is not working now 3D Print for Rear Step Plate Clip - https://forum.ih8mud.com/threads/3d-print-for-rear-step-plate-clip.1349251/. Luckily I already downloaded it.

Stalled on some updates as I need to buy a 200 in the next few months as the family is growing and airbags and abs are sometimes nice.