Build 1st FJ40, '76 - SMOKEY - Puttin’ her Back Together

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Edit: It could be the camera lens. It's really hard to tell. When I zoom in on the far-away picture it looks better.

Edit II: put long straight edges against the outside of the tires and measure at the bottom, then across the engine compartment. They should be the same if all is well. 0 degrees of camber.

That little bend in the tie rod is not causing what I'm seeing. I'm afraid that front end has seen some flight time. It might not be so noticeable when driving, but it will surely make your tires wear out funny.

It probably needs a knuckle rebuild anyway, and a new housing can be found cheaply enough.
 
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you asked.....

1. ditch those awful tires and wheels and try to source original or close to original steel wheels and some 32x10.50 or 9.50 tire.

2. Get an Aisin carb and oem aircleaner.

3. find the guy that hosed maroon all over everything and give him a black eye.

4. Get it mechanically sound (brakes, fuel, spark, steering, idle, etc.. all per FSM)

5. Enjoy it for a while and then start slowly fixing body issues.

good luck! we are all here to help.

1. No, no, I'd rather hear straight up, fully biased opinion. I agree on the wheels, and hence the tires - I was 16 about 30 years ago.

2. trollhole carb. Got it.

3. Here's for the guy who painted her: :bang: That truly is going to be a pain down the road. It is everywhere in the engine bay. I guess it held off some of the rust for a while.

4. Roger that. Not quite up on all the lingo yet. FSM? Factory Specified Manual? (*searching the internet*) Hmm, let's see. Flying Spaghetti Monster. Nope. Female Seeking Male. Nope - too bad though. Finite State Machine. From my engineering classes, but nope. Free Speech Movement. What Obama is trying to shut down... oops, did I say that out loud? Hopefully Factory Specified Manual is close enough.

5. AGREE - drive and enjoy it. Not going to go all "frame off" on it. I want to be able to have my kids learn a stick on it now, then make it nice after they are gone (and can't bash it up). This will be a fun project for the next few years (and then some hopefully).
 
Factory Service Manual.

images


Have you been touched by His noodly appendage?
 
BTW, I have a bumper that was bent almost exactly like that one is. I put a strap on the end and tried to pull my dually when it was in parked on asphalt. A few tugs and some taps with a 5 lb sledge and it's almost like new.

You could probably get that tie rod pretty straight with a floor jack too.
 
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Vae Victus said:
Trollhole has the original Aisin carbs?

Re the Aussie 2F air cleaner: just go to the AU K&N website?

thanks,
Scott

Trollhole has repro carbs which are effectively identical to the Aisin and have developed a good reputation.

Have your sister get it from a wreckers.if she's on Adelaide I can probably source it for her.

Air cleaner from either Sprint auto parts or Supercheap auto. They will likely have it in stock. She can just ask one of the blokes at the counter.
 
nice find, as others have said..first thing is the motor, brakes and cooling..then drivetrain. once those are secure,you can drive her..then the fun begins..start off by learning to "Fib" this will be needed if your married..try this " No Honey, our savings were invested in gold futurs..not fj's" not hard with practice..But, all kidding aside, ive found this site to be the most helpful bunch of guys/gals ever. dig in,follow advice and enjoy.
 
Fire in the Hole!

First:
Brakes.

If your brakes work and dont leak ...

Next:

Change all your fluids. ...

New fuel, an air cleaner, and start it up.

good luck

..then the fun begins..start off by learning to "Fib" this will be needed if your married..try this " No Honey, our savings were invested in gold futurs..not fj's" not hard with practice..


Guess I should have listened to your advice, but I started it up and decided to slowly drive it to see what worked and what didn't. We have a 1/2 mile long access road to our house and I ran it down that at a slow 10-15 MPH in 1st - 3rd gears.

Engine ran well, but something was making a loud rubbing/squealing rotational sound, not in the fan area, not in the engine block area, but in the area shown in the photo below.

After running for about 10 minutes, (I was actually just idling in the field and the bottom of the driveway waiting for my wife and kids to drive up so I could surprise them with the running '40) it began to make a very loud sound. Not a squeal like a belt, not a grinding noise, hard to describe. Needless to say, I said I needed to get the heck out of there and back to the house (uphill the whole way of course).

I started to motor up the hill and could tell something was wrong. I began to lose power and could smell a burning smell. Once I hit my true driveway (and of course at this time my wife and kids had pulled in right behind me and were watching my new baby die), the car just shut off suddenly - no electrical, motor just turned off completely as if I'd turned the key.

I put it in first gear since the eBrake is crap, and since I'm now on a 5% grade going up to my house, popped the hood and saw...... FIRE! The wiring leading to the thing in photo 1 was burning. I said "Oh sh##!" and started blowing. LOL. It blew out quickly, but clearly the sound and the trouble is with that component pictured. The starter! Didn't know what it was until just now (thank you Haynes manual).

Oh, and now I think I know what happened. When I was starting it, the key would just stay in the startup position without me having to hold it. Once the truck finally started, I just left it in that position, not thinking to play with it to see if it would turn back a little, and thus disengage the starter. So, I guess the starter was still trying to engage, and that was the noise I heard? Could that be? It was not the grinding noise you hear when you try to start an already started "modern" car.

So, the wife is very aware and very wary of this new project I've purchased. No way I can hide it now. The only wise thing I did was to NOT mention the word FIRE to her when describing my troubles.

I guess I can move "starter repair/replace" up near the top of the list now.

My list is looking like this:

1. Brakes - review and fluids (they are a bit mushy)
2. Fluids - coolant, trans, oil, diffs
3. Starter rebuild/replacement. What about the key
4. Wiring check around starter - likely replace small leads that were on fire!
5. Clean out the dirt and crap inside. Get a cover and cover it to keep any more rust from happening once I dry it out.
6. tires/wheels?
7. Side Mirrors - where the heck are those anyway?
8. Blinkers replaced on front. Neither works.
9. Blinker relays - left side doesn't blink it just comes on and stays on
10. Headlight replacements. Can I go LED? Will I need a larger alternator? One headlight is broken now, so at least 1 replacement.
11. Fan control troubleshooting. Feels like a baby deer blowing on me.
12. Heater doesn't heat.
13. Basically everything electrical is shot - probably an entire wiring harness replacement.
14. Wiper troubleshooting. They do not come on.
15. Choke - does it work?
u. Interior stuff - rear seats, seat belts up front and rear,
v. AC installed. This is Tennessee. It is ungodly hot about 75% of the year.
w. Get plates and title taken care of (once it runs)
x. Saginaw Power Steering
y. Rear Disk brakes
z. Body stuff - rust, painting, door hardware, window and hood hardware, new windows?, new rubber all around, getting the doors to close properly, etc.

Yea, that looks like about a couple week's work.

Open flame in the engine bay is never good.
1-IMG_4510.webp

Stranded. Of course at the bottom of the hill.
2-IMG_4513.webp
2-IMG_4513.webp
1-IMG_4510.webp
 
Edit: It could be the camera lens. It's really hard to tell. When I zoom in on the far-away picture it looks better.

Edit II: put long straight edges against the outside of the tires and measure at the bottom, then across the engine compartment. They should be the same if all is well. 0 degrees of camber.

That little bend in the tie rod is not causing what I'm seeing. I'm afraid that front end has seen some flight time. It might not be so noticeable when driving, but it will surely make your tires wear out funny.

It probably needs a knuckle rebuild anyway, and a new housing can be found cheaply enough.

BTW, I have a bumper that was bent almost exactly like that one is. I put a strap on the end and tried to pull my dually when it was in parked on asphalt. A few tugs and some taps with a 5 lb sledge and it's almost like new.

You could probably get that tie rod pretty straight with a floor jack too.

Thanks Eddie, you are making it sound more easy than it all looks right now. I'll measure the toe once I get 'er back up to the house.
 
the bezel is upside down :doh:

and I couldn't see any spring bushings left . . .

but, it's got more of a rear sill than mine :o

like others said, enjoy driving it :steer:
 
Hello all, lots of new FJ40 owners today. Glad to be one of them!

Before you say it - the Bezel is upside down. I know, I know.

the bezel is upside down :doh:

and I couldn't see any spring bushings left . . .

like others said, enjoy driving it :steer:

Ha, beat you to it!

So, two questions - spring bushings are located at the ends of the tie rods? Yes? No?

And, I've been wanting to ask you this since I started reading the forum a few weeks ago - what's a hand throttle?

Thanks for the observations.


Scott
 
So, two questions - spring bushings are located at the ends of the tie rods? Yes? No?

spring bushings are rubber or polyurethane bushings that go into the eyes of the leaf springs and provide cushion around the bolts/spring pins the leafs are mounted on

And, I've been wanting to ask you this since I started reading the forum a few weeks ago - what's a hand throttle?

a hand throttle is an attachment to the gas pedal that lets you pull the pedal by hand - it's meant to give you a third foot when you are on the clutch and the brake and starting uphill in a manual transmission rig :hillbilly: - others use it to rev up the RPMs while they have the winch or an air compressor running off the battery
 
The picture with the poor baby stranded with the rock behind the tire...Is that your house? Amazing if it is. As for the 40 good find. You had me laughing with the fire story. Don't worry though. When growing up one of my Dad's projects caught fire. I still tell that story 20 years later. You seem to have a solid plan. Keep the faith.
 
The picture with the poor baby stranded with the rock behind the tire...Is that your house? Amazing if it is. As for the 40 good find. You had me laughing with the fire story. Don't worry though. When growing up one of my Dad's projects caught fire. I still tell that story 20 years later. You seem to have a solid plan. Keep the faith.

Thanks Phares, yes, that's the abode. Sits up on a hill, makes it look imposing. Yes, I'm still chuckling at my fire fighting skills - BLOW DA*MIT, BLOW!

I need encouragement...

Scott
 
squirt a little tri-flow/pb-blaster/wd40/ into your ignition cylinder.

Man, I've got to get with the "renovate, rejuvenate, recycle" mind set. I keep thinking, "replace, buy new"!

Thanks - will do FishTaco. (Fried or Grilled by the way?)
 
So, what did I do to the vehicle when it caught fire? Did I short the alternator, sieze the starter and lock up something? Fry a fuse? It just cut off with no spark from the key.

What was causing the loss of power as it came closer and closer to catching fire?

"He's dead Jim. "
 
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