1HZ install into a 1978 FJ40

[crushers]

Functioning wipers, functioning heater/AC, PS box are issues that were unknown to me at time of delivery.

When I was reassembling the wiring harness I tested the wiper harness and the power flowed properly. When I installed the wiper it was working on one speed so it is natural to assume the fault was either the switch (which needed replacing due to intermittent signal to the washer motor) or the wiper motor itself.
Since the motor was 30 years old it made sense to replace it anyway which we did. Due to the rush at the end the switch was ignored until delivery of the truck and then the "ooops" reared its ugly head and you were saddled with the concern.
This is painful, frustrating and irritating to both of us.

The Vintage air system is not a quality unit, it is functional. Be VERY careful when "pulling it out" it is flimsy and can break plus there is little room for maneuvering it around so the AC lines could be damaged. Once again a frustrating ooops for both of us. Again, the time issue did not allow me to test the unit here.

The power steering box functioned well on the drive across Canada towing the military trailer so there was no inclination at that time of failure. We did not replace it due to this experience. In hind sight we should have. When dealing with used parts there is a chance of them failing. Unfortunately, it seems it has decided to fail.

In hindsight, I should have not rushed the last few steps of the assembly. You had waited this long and another couple of weeks would have made little difference. I wanted it down to you to enjoy the fall with. In the end it made no difference due to the weather settling in as I arrived.

I ask certain questions when a build starts for a reason. If the customer dictates "I want a vehicle I can go tag bear and cougar. I want a vehicle I can drive to the tip of Argentina and back" then that is the direction I head with the build.
If someone says I want a show truck then the build will take a completely different heading.
What this shows is how important customer / builder communication / relationship are to satisfaction of the completed unit to all involved.

I built you a DD / off road adventurer and I would love to be able to personally instruction and guide you further on the abilities of this unit.

You are looking the truck over with a critical eye, which is good since it helps me to see what flaws I missed.
The list you made me of the imperfections while I visited your beautiful city were minor in most articles.
The wipers shocked me and upset me.
When you pointed out the paint job quality and mentioned the show room aspect was the first time I heard of this expectation. To be honest, I don't think I could have finished it to the perfection that you expected and I probably would have turned the build away.

At this time, you are not enjoying the truck, right now it is a flawed show piece sitting eating at you. Once you have it in the hills and can feel the abilities, the sure footedness, the "my god this thing rocks" experience then maybe you will step back and re-evaluate the build for what it was designed for.

Although you are not happy with the final finish of the vehicle, I am.

I enjoyed the build, I enjoyed the comments of those that saw the truck first hand in Ontario and I am proud of the build especially due to the magnitude of the modifications.

Should I undertake a build such as this again I would not put a time limit on it nor would I put a budget amount. This build evolved as it progressed from a simple 1HZ/H55F install into a fiberglass truck into a one off unit and the time and money confirms this.

I do find it insulting that you are picking the build apart, I built this truck for a 5 ft inspection; I never hinted, or expected, it was going to be perfect at 1 ft.

I do apologize for the non functioning AC, wipers and PS issues.

Seasons greetings and to an enjoyable 2010 to all that are following this thread.

 

[Rusty Phillips]

the power steering still sounds horrible, even with the leak fixed and topped off. will have to figure out if i have bad seals, gears, etc.

ok, that's the latest gents. hopefully more soon.

Otter

when you refilled the PS reservoir after finding the loose fitting on the pump - what fluid did you use?

im 98 % (I'll never say 100% about ANYTHING ever again in my life, but Im pretty damn close to it in this case) certain that the HZ like my FZE takes ATF in the PS system and not power steering fluid

if you put PS fluid in your PS reservoir that may be the cause of cavitation / air entrainment and moans and groans in the system

its an easy fix - but complicated by lack of room on your truck - take return line off of pump and route a hose to a bucket jack front up and turn wheel left to right until empty

fill reservoir up with ATF and then turn engine on for 5 seconds & repeat until fluid comes out looking like new red ATF

a lot of threads on mud about PS whine and flush procedure

heres but one https://forum.ih8mud.com/80-series-tech/339796-power-steering-whine.html

look for where cruiserdan mentions adding a little downey fabric softener to make your PS fluid smell better as well... I cant find it right now (got to go to work)


My hope - as a friend of Wayne & Bernadette's, and as someone who shed some blood sweat and tears and 4 letter words over your truck, is that you you get your issues resolved to your satisfaction, and are able to enjoy the kick ass truck that you have there

my hope as a mud member since 2004, is that you keep posting pics here of the truck as you put your finishing touches & personalize it, you keep asking questions of the mud community (so that we all can learn) and that the truck does not spend the rest of its life on only pavement - that you get it out and get it dirty once in a while..... and that you post pics of that as well.

one other comment - if I was to build this truck - having learned from this one - (starting from scratch) - considering how tight this engine bay is - would be to ditch the intercooler and put both the batteries in compartments under the rear of the truck (or maybe in a compartment under the drivers floorboard)

 

[OtterX]

no need to feel "insulted" wayne, rather i suggest that you sit back and review the positive aspects i prefaced all my replies with, then take a breath and learn from this expensive and ongoing lesson as i did and am still.

i would disagree with your perception that i am picking the build apart, rather i would hope that you would support my objectives to find solutions for the unfinished elements from the PS to AC and wipers. all issues unrelated to my personal opinions of the fg body work, that is certainly subjective and as i noted mine and mine alone.

as i have, consider this as an educational experience, not an insulting one.

its pretty clear we had ultimately had very different definitions of what "finished" was. also, when we began our negotiations, i listened very carefully to your opinions, and criticisms about icon, hilltop and others, leading me to select you as the builder. i also was very clear from the getgo about my expectations of not only the performance, which you felt very competent in achieving and explained the semantics behind them; and i feel this rig will eventually be quite capable of, but also in appearance. i am in the business of excellence, attention to detail, form follows function, performance as a designer and user in the field. i have learned over many years thru trial and error, that i do not enter any transaction personally or on a corporate level, without communicating those parameters. i have the emails describing my criteria, and then your replies expressing your confidence in achieving those various objectives.

so, with no desire to be counter productive and flogging the issue that we did not have a clearer understanding of our differences in opinions and expectations, i trust that you will be able to provide technical advice for the unfinished elements of the rig you left me with. i have not heard from you in many weeks/few months since after attempting to reach you by email confirming that the box of manuals and misc parts you promised to send had been sent upon your return home and after your vacation. also the missing AC(a unit of your recommendation) info would be of great help too.

i plan on enjoying this rig as much as i have free time for. it will be used for work and play; in the bush and also occasionally on display for the company. this truck is to be and will be driven, daily, and also on longer trips. right now, the one major element holding it back is the problem PS pump. since this part was from a 70 series if i recall, maybe you have some sources to point me to?

while i have the "satisfaction" knowing that this is one unique and eventually capable truck, you might consider that when compared to other entities i considered b4 going with you, that 2 years without a cross country relocation, or squeezing in other truck jobs inbetween should have been sufficient for this build, and as for budget, i shudder to think how much more could have been spent on this project. i really scraped to pay for this and am paying for it still. most of us are not in the same income league as the CEO of A&F.

in the world of choices from various service providers, i made mine with you. as the provider of said services, you should strive to improve, learn from your mistakes, and take a look around at your competitors and learn from what they do better. as for myself as the principle of a company, i do all the time. i read my customers' constructive criticisms, complaints, compliments weekly and learn from them to improve my business. i don't just apologize when i or any of my subordinates make a mistake, but i then do what i can to make it right.

keep in mind that as entity entrusted to a paid, turn key, vehicle related service, the $ spent on this project with you could have fielded an absolute top end hardtop icon with extras, 2 g-wagens, or 2-3 very well built US fj40 gassers.

what is done is done. i am trying to get the rig road and trail worthy and drive the **** out of it before i have kids. hell, i'd like to give it to one of my kids someday to enjoy.

i would like to continue to share my ongoing work on mud and expect that you will be around to help out when you can.

cheers,

Functioning wipers, functioning heater/AC, PS box are issues that were unknown to me at time of delivery.

When I was reassembling the wiring harness I tested the wiper harness and the power flowed properly. When I installed the wiper it was working on one speed so it is natural to assume the fault was either the switch (which needed replacing due to intermittent signal to the washer motor) or the wiper motor itself.
Since the motor was 30 years old it made sense to replace it anyway which we did. Due to the rush at the end the switch was ignored until delivery of the truck and then the "ooops" reared its ugly head and you were saddled with the concern.
This is painful, frustrating and irritating to both of us.

The Vintage air system is not a quality unit, it is functional. Be VERY careful when "pulling it out" it is flimsy and can break plus there is little room for maneuvering it around so the AC lines could be damaged. Once again a frustrating ooops for both of us. Again, the time issue did not allow me to test the unit here.

The power steering box functioned well on the drive across Canada towing the military trailer so there was no inclination at that time of failure. We did not replace it due to this experience. In hind sight we should have. When dealing with used parts there is a chance of them failing. Unfortunately, it seems it has decided to fail.

In hindsight, I should have not rushed the last few steps of the assembly. You had waited this long and another couple of weeks would have made little difference. I wanted it down to you to enjoy the fall with. In the end it made no difference due to the weather settling in as I arrived.

I ask certain questions when a build starts for a reason. If the customer dictates "I want a vehicle I can go tag bear and cougar. I want a vehicle I can drive to the tip of Argentina and back" then that is the direction I head with the build.
If someone says I want a show truck then the build will take a completely different heading.
What this shows is how important customer / builder communication / relationship are to satisfaction of the completed unit to all involved.

I built you a DD / off road adventurer and I would love to be able to personally instruction and guide you further on the abilities of this unit.

You are looking the truck over with a critical eye, which is good since it helps me to see what flaws I missed.
The list you made me of the imperfections while I visited your beautiful city were minor in most articles.
The wipers shocked me and upset me.
When you pointed out the paint job quality and mentioned the show room aspect was the first time I heard of this expectation. To be honest, I don't think I could have finished it to the perfection that you expected and I probably would have turned the build away.

At this time, you are not enjoying the truck, right now it is a flawed show piece sitting eating at you. Once you have it in the hills and can feel the abilities, the sure footedness, the "my god this thing rocks" experience then maybe you will step back and re-evaluate the build for what it was designed for.

Although you are not happy with the final finish of the vehicle, I am.

I enjoyed the build, I enjoyed the comments of those that saw the truck first hand in Ontario and I am proud of the build especially due to the magnitude of the modifications.

Should I undertake a build such as this again I would not put a time limit on it nor would I put a budget amount. This build evolved as it progressed from a simple 1HZ/H55F install into a fiberglass truck into a one off unit and the time and money confirms this.

I do find it insulting that you are picking the build apart, I built this truck for a 5 ft inspection; I never hinted, or expected, it was going to be perfect at 1 ft.

I do apologize for the non functioning AC, wipers and PS issues.

Seasons greetings and to an enjoyable 2010 to all that are following this thread.

 

[OtterX]

that is a very helpful tip rusty, thank you.

i was unaware of the ATF versus PS fluid and went only with what wayne instructed me to do when we discovered that it was below levels on our test day.

i have been topping it off with PS fluid ever since. the first thing i did upon exiting the 4x4 course was get to a gas station and get the ps fluid to top off at wayne's direction.

i would love to get confirmation from wayne on this topic. i do not want to be putting the wrong fluid in!

yes, the tightness of the engine bay is recognized. with the number of mentions, i think its been quite a point of great pride and frustration from wayne over the course of this build.

Otter

when you refilled the PS reservoir after finding the loose fitting on the pump - what fluid did you use?

im 98 % (I'll never say 100% about ANYTHING ever again in my life, but Im pretty damn close to it in this case) certain that the HZ like my FZE takes ATF in the PS system and not power steering fluid

if you put PS fluid in your PS reservoir that may be the cause of cavitation / air entrainment and moans and groans in the system

its an easy fix - but complicated by lack of room on your truck - take return line off of pump and route a hose to a bucket jack front up and turn wheel left to right until empty

fill reservoir up with ATF and then turn engine on for 5 seconds & repeat until fluid comes out looking like new red ATF

a lot of threads on mud about PS whine and flush procedure

heres but one https://forum.ih8mud.com/80-series-tech/339796-power-steering-whine.html

look for where cruiserdan mentions adding a little downey fabric softener to make your PS fluid smell better as well... I cant find it right now (got to go to work)


My hope - as a friend of Wayne & Bernadette's, and as someone who shed some blood sweat and tears and 4 letter words over your truck, is that you you get your issues resolved to your satisfaction, and are able to enjoy the kick ass truck that you have there

my hope as a mud member since 2004, is that you keep posting pics here of the truck as you put your finishing touches & personalize it, you keep asking questions of the mud community (so that we all can learn) and that the truck does not spend the rest of its life on only pavement - that you get it out and get it dirty once in a while..... and that you post pics of that as well.

one other comment - if I was to build this truck - having learned from this one - (starting from scratch) - considering how tight this engine bay is - would be to ditch the intercooler and put both the batteries in compartments under the rear of the truck (or maybe in a compartment under the drivers floorboard)

 

[crushers]

from the manual... something i did not know (since decades ago Toyota service had informed me to use PS fluid): (thanks Rusty)

Power Steering ATF Dextron or Dextron II
7 series system 27.4 L and reservoir is 13.2 oz on a stock system, it should be close with this system.

Otter, this has been and continues to be a learning experience.

email sent.

 

[OtterX]

roger that. will flush and replace with ATF!

from the manual... something i did not know (since decades ago Toyota service had informed me to use PS fluid): (thanks Rusty)

Power Steering ATF Dextron or Dextron II
7 series system 27.4 L and reservoir is 13.2 oz on a stock system, it should be close with this system.

Otter, this has been and continues to be a learning experience.

email sent.

 

[sandcruiser]

for sure PS fluid in the steering system can make leaks/groaning worse

down here, there are Castrol distributors who have a fancy machine that hooks up to the reservoir and pumps the old fluid out, fills with some sort of hot cleaner, then drains/fills with new fluid.

Very nifty. The last time I did it, I was pleasantly surprised by the amount of crud that came out with the old fluid. Do be sure to recommend that they fill with ATF as the two machines are the same, but different.

 

[crushers]

manuals are heading out tomorrow.

post up the length of head rest retainers you got from Dan so i can compare. i will do some digging once the shop is back together and see if i have the ones you need.

 

[crushers]

to help:
here is the actual cost of the tub and assorted parts from Gozzard.


FRP Cruiser parts MSRP Cdn
G1 GC 101 Tub GRP Part Only $4,350.00
G2 GC 104 Fenders GRP Part Only $525.00
G3 GC 108 Bib GRP Part Only $230.00
G4 GC 110 Bezel GRP Part Only $260.00
G5 GC 113 Hard top sides GRP Part Only $980.00
G6 GC 114 Roof GRP Part Only $1,010.00
G7 GC 116 Windshield GRP Part Only $825.00
G8 GC 117 Hood GRP Part Only $717.00
G9 GC 118 Tail light guards GRP Part Only $75.00
G10 GC 120 Ambulance doors GRP Part Only $803.00
G11 GC125 Drivers door GRP Part Only $1,200.00
G12 GC 126 Passenger door GRP Part Only $1,200.00
G13 GC 128 Fuel tank cover GRP Part Only $215.00


Sub total $12,390.00

not shown the drop boxes and the hood scoop which come in at $2500.

 

[OtterX]

manuals are heading out tomorrow.

post up the length of head rest retainers you got from Dan so i can compare. i will do some digging once the shop is back together and see if i have the ones you need.

good to hear.

will measure retainers when i am back home at the end of dec and relay to you.

also good to see fg breakdown.

cheers,

 

[crushers]

you just need one set right or is it both seats, i can't remember.

 

[OtterX]

you just need one set right or is it both seats, i can't remember.

both seats would be good.

 

[bsmith123]

sag power steering

Thanks for the help so far--just one more nagging thought on the 1hD-t into my 40---I have a sag steering install---will the steering shaft be in the way on its route to the SAG gearbox

Would the 1hdt mean going to the 60 steering instead? that might kill this for me?

thanks

B Smith

 

[crushers]

depends on where the box is situated. if the shaft is over the frame then no big issues, the problem is where the starter and the shaft are situated. take a pic and post it up, straight above the shaft and full shaft length showing.

 

[bsmith123]

shaft

still working on thtat pic but I went by the shop where it is getting painted today and forgot my camera

the circle i painted on this pic is approx where the shaft crosses from overtop the fame inboard on its way to the gearbox so it is forward of the header pipe but aft of the shock mount

(this is an old pic and it has since been converted to SAG power steering)

Appreciate your help and the inspiration of the 1hz build!

 

[ColoCruiserJeff]

I must chime in....even though this build is much older - it needs to come to the top again.

Is the unit still operating on the road as a DD?

If so, please let us know what type of fuel performance you're getting out of the 1HZ / H55 set-up?

I'm contemplating doing this motor swap...and relative fuel economy is vital.

Please post-up the status of the build -

Thanks again!

 

[OtterX]

I must chime in....even though this build is much older - it needs to come to the top again.

Is the unit still operating on the road as a DD?

If so, please let us know what type of fuel performance you're getting out of the 1HZ / H55 set-up?

I'm contemplating doing this motor swap...and relative fuel economy is vital.

Please post-up the status of the build -

Thanks again!

It is still using the swapped 1HZ motor. The rig itself has been undergoing a slow transformation since it's delivery to me, so unfortunately besides a couple of trips to OEX in AZ, it has been mostly in varying stages of mechanical and electrical upgrades or repairs as time, funds, and resources allow. Some changes which might have affected fuel economy was the installation of a boost compensator(solved all my black smoke issues) from the original high altitude one which was on the motor as it came from Wayne.

During the trips to AZ, it was opportune times to calculate mpg. This was driving with a passenger and an overland camping load for 1 week for 2 people, plus recovery gear including AL sand ladders, 10L water, 10L extra fuel, and some extra weight of plinking ammo. Didn't have an exact weight and can't take into account for high winds. This was not in controlled "scientific" conditions. So take all of the estimates with a grain of salt.

@ 75-80mph on flats, we were averaging roughly 15mpg. During one particular stretch with alot of uphills with a 1/4 tank refill between intervals, it was as low as 11mpg.

@ 65mph on flats, we were averaging better at almost 18-19mpg.

@ 55mph (rare) on flats, our best guess was 22+ mpg.

During my trips(my only real measurable driving except for going to OEX) to Murak from SF (about an hour drive averaging 55-65mph), without load and just me the driver, the mpg seemed to average around 23 or better?

This is a long ass thread and without scrolling thru all the pages, this is my best recollection of the changes in this build since my last post:

• Isolated 3 bad electrical drains and virtually rewired the entire truck and installed a National Luna dual battery controller. No more dead battery, fussing with dual kill switches, etc. Now cranks strong, all 12V accessories work consistently.
• Gear shift lever just came off the base during one day in traffic. Yikes. Scary. Drilled some thru holes and pinned the hollow part of the shaft into the receiving end of the base. Voila fixed. Much better and confidence inspiring than what appeared to be a silicon, epoxy solution previously.
• Discovered and replaced all interior low grade sheet rock screws with stainless machine screws.
• Found a bad wheel bearing and replaced.
• Dismantled the Vintage Air AC unit and discovered a dropped screw causing an annoying sound whenever the unit was turned on and the fan was hitting it. Remounted the AC unit for better position. Drilled a hole and sealed hole in footwell for condensation drip tube. Blows reasonably cool now.
• Installed steering column collar to take up rattle and slack.
• During last trip to OEX, the intercooler bracket cracked clean, so replaced with new bracket and some rubber bushings for mounts to help with the vibration and metal fatigue which looks to be apparent cause of the first break.
• Replaced door latches and tweaked the action so the doors would consistently open and occupants could egress without using the window.

These are from the recent todo list for the past year.

This is my first diesel but second FJ40. It has been a very wild ride and bumpy road and a definite learning experience. Overall, I am very pleased with the 1HZ motor. It was more powerful than anticipated. Torque is a given. I run pump LSD, 100% bio or mixes there of. I would like to see 25mph+ performance, but haven't experienced it.

I try not to push it over 70mph when on the road and keep it around 65mph most of the time when driving to and from Mudrak. I only push it to 75-80 on certain long flat stretches to the OEX in AZ. 55mph is the optimum freeway speed for best fuel economy from what I understand.

This rig was intended as a fully loaded expedition build to run in Baja and some day to Tierra del Fuego. Lot's stuffed in it and going on the engine bay. I've had it going on 3 years or so now and I am finally getting it to where it is electrically and mechanically "sound", or at least subjectively, where I want it to be. Since then, I've gotten married and had a kid, so I wish now it was a troopy to carry all of us + 2 dogs. Anyone want to trade?

HUGE props to Mudrak in helping me rounding out and working out the lingering issues/upgrades with this baseline rig.

 

[ColoCruiserJeff]

OtterX-

Thanks for the quick reply. Congrats on the wife and kiddo....that's an awesome ride in itself.

I personally realized that my FJ40 was not going to be the rig of choice for us as a now, family of 4. The 40 just doesn't have the room that is needed for the ARB Fridge and camping gear for 4 of us...for more than a day or two.

I think 25mpg is achievable...as I've heard from good sources that 33mpg is reachable with a finely tuned 2BT and H55 in a 40 on 33" All-Terrains.

The 1HZ has more torque, weighs a little bit more than a 2BT...so I'm assuming that those extra ponies are needing to be fed!

We'd love to learn more about your progress with your 40 - please post up more pics...start a new thread on it if you choose to share.

Thanks again for sharing your experiences and your changes / upgrades to your rig - we're all learning from eachother's choice of modifications to our rigs and this is truly a work of art to admire! You have an amazingly capable rig there!

Best regards,
Jeff

 

[OtterX]

OtterX-

Thanks for the quick reply. Congrats on the wife and kiddo....that's an awesome ride in itself.

I personally realized that my FJ40 was not going to be the rig of choice for us as a now, family of 4. The 40 just doesn't have the room that is needed for the ARB Fridge and camping gear for 4 of us...for more than a day or two.

I think 25mpg is achievable...as I've heard from good sources that 33mpg is reachable with a finely tuned 2BT and H55 in a 40 on 33" All-Terrains.

The 1HZ has more torque, weighs a little bit more than a 2BT...so I'm assuming that those extra ponies are needing to be fed!

We'd love to learn more about your progress with your 40 - please post up more pics...start a new thread on it if you choose to share.

Thanks again for sharing your experiences and your changes / upgrades to your rig - we're all learning from eachother's choice of modifications to our rigs and this is truly a work of art to admire! You have an amazingly capable rig there!

Best regards,
Jeff

You're welcome Jeff. Glad to offer some notes. Hoping to get the rear diff e-locker working again and take her out to the Lost Coast about 4.5hrs north of SF at the end of the month. Should be a great run. My wife will follow in our 2010 FJ Cruiser.

33mpg would be a dream. I'd be happy with a running average of 25mpg someday if possible. Now if we could only get those diesel LC70 wagons into North America, wouldn't that be something! I saw those variants all over the Top End in Australia a year back and was mighty envious!

 

[swamprunner]

you can get them if you have the $$$. Call west coast cruisers. He has one sitting in san diego right now