1HZ install into a 1978 FJ40

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engine mounts...
1978 HJZ40 build 104.webp
1978 HJZ40 build 105.webp
1978 HJZ40 build 106.webp
 
okay, where did we leave off?

when installing the 60 series steering box onto a 40 series you need a 7* series drag link and new 7* tie rod end and the 4* series at the cross link. this allows for a non-welded steering install. SWEET!!

<thanks again Bruce>

all in all a nice clean install. more on this at time of reinstall.
1978 HJZ40 build 108.webp
1978 HJZ40 build 109.webp
 
now to remove the axles and old springs.
it is easier to just torch the old ubolts off. but be carefull not to cut into the housings.
also on older (decades old) spring busings and pins it is easier to just heat the end of the spring red hot and the bushing will melt. this breaks the bond between the bushing and the pin... bang bang and the pin is out.
1978 HJZ40 build 110.webp
1978 HJZ40 build 111.webp
 
next, this frame had the Wayne special lift. a true 3" lift that kept the caster and camber at stock calibration. this lift was 11 years old and it was a bitch to remove. of course care had to be taken not to damage the frame. the fixed end spring perches are being reused.
1978 HJZ40 build 112.webp
1978 HJZ40 build 117.webp
1978 HJZ40 build 116.webp
 
the final test to make sure all fits still.
the old rivits were removed and there will be grade 8 bolts to replace the rivits.
removal of the side step supports for sand blasting and powder coating.
1978 HJZ40 build 118.webp
1978 HJZ40 build 114.webp
1978 HJZ40 build 115.webp
 
reinforcment plate for the 60 series steering box... i wanted a step look when finished...
1978 HJZ40 build 130.webp
1978 HJZ40 build 131.webp
1978 HJZ40 build 132.webp
 
removal of some more unnecessary artifacts...
rear engine mount off the top of the frame
the middle rear body mounts since the fiberglass body has no need for them.
1978 HJZ40 build 137.webp
1978 HJZ40 build 139.webp
1978 HJZ40 build 138.webp
 
finally the fun begins
sand blasting, this is when the beauty begins to show...
1978 HJZ40 build 144.webp
1978 HJZ40 build 145.webp
1978 HJZ40 build 146.webp
 
from the sand blasters it went straight to the powder coaters, i wasn't allowed in the booth but these are some after the fact shots for the ride home...

looking pretty good!!
1978 HJZ40 build 151.webp
1978 HJZ40 build 152.webp
1978 HJZ40 build 153.webp
 
monday is another day...
i feel the frame looks nice and should last for a long time to come.
pretty good for a 30 year old frame...
1978 HJZ40 build 154.webp
 
update Oct 29th:
back on the rottiserie
reinstalling the fix end spring mount with grade 8 bolts.
the new spring bumpers
1978 HJZ40 build 158.webp
1978 HJZ40 build 160.webp
1978 HJZ40 build 162.webp
 
when i install spring packs with the poly bushings i lube them with antiseize. i find this gives the bushings a chance to move before the grease is pushed in.
some people disagree... oh well.
1978 HJZ40 build 169.webp
1978 HJZ40 build 170.webp
1978 HJZ40 build 171.webp
 
insert the shackel first
the extended shackel makes easy work for the 40 series spring kits. the stock length are TIGHT to fit.
1978 HJZ40 build 172.webp
1978 HJZ40 build 173.webp
1978 HJZ40 build 174.webp
 

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