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

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Hoz FJ40 CO said:
Bfgoodrich makes a 30 x 9.5 x 15 mud terrain. They look cool but are squirrelly on the road. A 10.5 width is the way to go for smooth/safe driving.

Cruiser Corps makes a nice 4 core aluminum radiator. But your local radiator shop can re-core and dip your current one as well.

X2 in the clutch parts ... Go OEM.
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Thanks Guys - Hoz, been reading your latest build thread. Interesting. Pretty OCD dude! But, looks like you guys were doing most of the labor in your garage, so the weld/paint, pause, re-weld/re-paint cycle was not as expensive as pure outsourcing.
 
First Nut from the FJ40!

I took off the first nut today! The replacement starter arrived, and I pulled it off, pausing to take a picture of the first nut removed. Brought a tear to my eye... only because I realize how many more I'll be pulling.

The starter gear was pretty stripped out. Looks like it was stuck in the "on" position during my check ride the other day, thus causing the wires to overheat. You'd think the fuses would catch that, but not everything seems to be fused. Learning!

Still no life in the vehicle after changing - battery tested out to be dead. Must have shorted it out? Reads a volt or two on the multimeter. Nothing near the 11 it should be.

Man, the more I look, the more I see wrong.

Cover arrived too. Put it on to keep the rain on the outside of the vehicle until I can arrest some of the weather stripping, if not the rust.
 
Take your time and have fun. We've all been there. Once you finish your build you'll be an expert for the most part on what to buy or just enjoy the ride you have. I built a few before buying and keeping the 79 fj40 I currently have. It runs and drives now ($3k) later. Now time to make it pretty :-) if I were in your shoes I'd just replace the entire cooling system (radiator, all hoses, t-stat and gaskets), then move into new plugs, wires, battery, alternator then check all wiring and replace where needed. Get her running good and enjoy it for a while. Next summer or two, you will probably be ready to make her pretty. Good luck and have fun. We're all here when you need help.
 
Vae Victus said:
I took off the first nut today! The replacement starter arrived, and I pulled it off, pausing to take a picture of the first nut removed. Brought a tear to my eye... only because I realize how many more I'll be pulling.

Man, the more I look, the more I see wrong.
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Funny what happens when the rose colored glasses come off and you see what you REALLY bought for the first time. Haha

Don't fret too much. Take it one step at a time. Seriously I had to sit down and make a list, prioritize it, figure out costs and tools required for each part of the project. Once the overwhelming number of individual projects becomes a well organized list, it gets MUCH easier to tackle.

One thing at a time, and as others have said, you are part of the MUD community. This forum is probably the nicest, most helpful collection of car fanatics I've ever "met" on the Internet. They won't steer you wrong!
 
Oh, and congratulations on your first nut. If it didnt break, you are one step ahead of me :)
 
Thanks guys. It's all good - making a list, checking it twice.

Mystery hard line - why is this second line that appears to come from the gas tank just hanging loose in my engine bay? There is of course a primary fuel line, but then there is this.

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It is the hard line that is between the red vertical seam on the firewall and the wire bundle coming out of the firewall. Close up here:

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Looks like the fuel return line, which is missing due to the Weber. Doesn't really look like it's in the right spot though. Where does it go on the other end?
 
It is most likely a return line, or some other part of the '76 emissions control system. My truck has a hard line or two chopped on that side too, since they were incompatible with the 350 SBC.
 
There's a clutch hardline right there and charcoal canister hardlines on your firewall right there too.

But that line with the flare nut is a fuel line, either supply or return. Can you trace your supply and return lines and post up some pictures (including the fuel filter and fuel pump)?
 
subzali said:
Looks like the fuel return line, which is missing due to the Weber. Doesn't really look like it's in the right spot though. Where does it go on the other end?
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RWBeringer4x4 said:
It is most likely a return line, or some other part of the '76 emissions control system. My truck has a hard line or two chopped on that side too, since they were incompatible with the 350 SBC.
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subzali said:
...
But that line with the flare nut is a fuel line, either supply or return. Can you trace your supply and return lines and post up some pictures (including the fuel filter and fuel pump)?
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MicahMan said:
I have a return line that is no longer being used right there as well. I have a Trollhole carb and no need for the return! I capped mine because I'm too lazy to trace it back right now!
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Yes, It must be a fuel return line. I have a Weber carb in there - very good subzali! Makes me darn (sorry anti-cursing filter) nervous when I see all these loose connections.

Ok, also posted a question in another starter thread: truck is still dead after new starter, new battery, checking fuses, checking continuity of wires in wiring harness that were involved in the small blaze last week.

Any clues what to check?
https://forum.ih8mud.com/40-55-series-tech/724691-40-dead-after-starter-shorted-where-start.html
 
Vae Victus said:
Yes, It must be a fuel return line. I have a Weber carb in there - very good subzali! Makes me darn (sorry anti-cursing filter) nervous when I see all these loose connections.

Ok, also posted a question in another starter thread: truck is still dead after new starter, new battery, checking fuses, checking continuity of wires in wiring harness that were involved in the small blaze last week.

Any clues what to check?
https://forum.ih8mud.com/40-55-series-tech/724691-40-dead-after-starter-shorted-where-start.html
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You will find all sorts if wires and hoses that lead nowhere. At least you have the stock engine. You should see the spaghetti monster I'm dealing with...

Forgive me if this is a really stupid question but have you checked the fuses? They're under you're steering wheel in the cab...might have blown a couple...
 
Sorry it was a stupid question, just read your other thread...
 
I assume you mean front disks? They never had rear disks, stock, to my knowledge...

I believe they changed over to front disks just prior to 1976, I believe it was around September of '75. So sounds like your truck might have just made the cut. Just like my June '75 just barely didn't make the cut :bang:

So sounds like yours would be a 76 year model, built in late 75.
 
Yip. Yours is a '76. You would have some of the very first disks Toyota (or Araco, more specifically) made for the cruiser. My '76 was April I believe so not even close to the pop out rear vents.
 
RWBeringer4x4 said:
I assume you mean front disks? They never had rear disks, stock, to my knowledge...

I believe they changed over to front disks just prior to 1976, I believe it was around September of '75. So sounds like your truck might have just made the cut. Just like my June '75 just barely didn't make the cut :bang:

So sounds like yours would be a 76 year model, built in late 75.
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Rear disks? What are you talking about RWB? :wink:
 
Chamba said:
Yip. Yours is a '76. You would have some of the very first disks Toyota (or Araco, more specifically) made for the cruiser. My '76 was April I believe so not even close to the pop out rear vents.
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That's pretty cool. You guys are helpful as always.
 
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