Build $500 1992 FJ80 Rebuild

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Getting things organized & back on track.

The Roofnest Falcon has been airing out on warmer sunny days, so that's helped with some of the funk from sitting closed. Husband cleaned & treated all the seals and has been meticulous in making sure none of the flaps or edging are out of place when closing it - it's made quite the difference so far. He was able to salvage the condensation mat inside, although the included memory foam mattress went in the trash. We're hoping to convince a few friends to come over for dinner soon & help get the tent off the Land Cruiser for final cleaning.

We have a nice sleeping pad/bag duo that has worked well for tent camping, so I think we'll use it in the RTT to start out. Otherwise I have a link for the original memory foam mattress available from the manufacturer, along with a few upgrade options saved.

I ordered a new fuel pump, spindle nut, and 54mm hub socket from Cruiser Teq. It's past time to replace the worn out front axle & squeaky burnt brakes. Once those parts arrive, we should have space open in the garage for the Land Cruiser.

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Warm weather is here and we're making progress on the Land Cruiser.

We decided to divide and conquer our tasks. Husband dove into disassembling the passenger side axle. It's a nasty smelly mess of mixed axle grease and diff oil. 🤢 Definitely a good reason to buy a parts washer.

Unsurprisingly the front brake pads were toast. I ordered new pads & rotors a while back, so that should make a nice difference.

While husband worked on that mess, I opted to give the rooftop tent a thorough cleaning inside & out. A light vinegar & water solution combined with a medium stiffness interior brush helped to eliminate any remaining mold or mildew left on the fabric. There are still some stains to tackle, so it's airing out until my bottle of 303 bleach-free cleaner arrives. If that doesn't do the trick, I have a bottle of Star Brite that I'll try out on a test spot. Then it will be ready for resealing in a few places & a combo of 303 Fabric Guard and Nikwax Solarproof.

I'm going to bring back the to-do list & add a few more things to it:

Install new charcoal canister
Get spare tire mounted
Install passenger visor
Front brake pads & rotors
Engine & transmission mounts
New front & rear u-joints and hardware
Service front axle
Extend diff breathers
Install rear OME springs
Replace fuel pump
Fix power steering leak
Fix exhaust
Remove factory roof rack
Reinstall roof bars & tent


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Warm weather is here and we're making progress on the Land Cruiser.

We decided to divide and conquer our tasks. Husband dove into disassembling the passenger side axle. It's a nasty smelly mess of mixed axle grease and diff oil. 🤢 Definitely a good reason to buy a parts washer.

Unsurprisingly the front brake pads were toast. I ordered new pads & rotors a while back, so that should make a nice difference.

While husband worked on that mess, I opted to give the rooftop tent a thorough cleaning inside & out. A light vinegar & water solution combined with a medium stiffness interior brush helped to eliminate any remaining mold or mildew left on the fabric. There are still some stains to tackle, so it's airing out until my bottle of 303 bleach-free cleaner arrives. If that doesn't do the trick, I have a bottle of Star Brite that I'll try out on a test spot. Then it will be ready for resealing in a few places & a combo of 303 Fabric Guard and Nikwax Solarproof.

I'm going to bring back the to-do list & add a few more things to it:

Install new charcoal canister
Get spare tire mounted
Install passenger visor
Front brake pads & rotors
Engine & transmission mounts
New front & rear u-joints and hardware
Service front axle
Extend diff breathers
Install rear OME springs
Replace fuel pump
Fix power steering leak
Fix exhaust
Remove factory roof rack
Reinstall roof bars & tent


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AWESOME TEAM WROK!!!
 
AWESOME TEAM WROK!!!
Thank you! It feels good to get more issues on this thing fixed.

Small update:

Husband got the passenger front axle rebuilt with new seals & the birfield joint. Pad & rotor on that side were replaced as well. He noticed the small section of brake line that ties into the caliper was cracked & split in a few sections, so we ordered replacements for peace of mind. While waiting for those to come in, he decided to swap out the pad & rotor on the driver side and encountered this:

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The outer wheel bearing & race were rusted out and just barely hanging on. He said he couldn't spin it by hand. So good thing he caught that before it caused a meltdown. After finding that, he decided to go ahead and replace all the seals and bearings on that side as well. He had it all buttoned up with the new brake lines last night and we bled the brakes.

Next up: he will get it rolling again so we can back it out, pull the middle row seats & carpet, then back it in so he can work on replacing the fuel pump.

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Progress on the tent has been delayed by high winds or rainy days. So I'm hoping to tackle that after this weekend with the stain remover products. Once I'm satisfied with the outcome, it should only need a few spots resealed with Seam Grip & to have the the UV protectant & waterproofing reapplied.

We also found another deal. Iceco is clearing out their secondhand 12v fridges at half price, so we picked up the JP50 53qt model. It arrived yesterday and looks new. It cooled down quickly and is rather quiet other than a barely noticeable high pitched frequency from the compressor fan. My only disappointment is we didn't get the insulated cover or 12ft DC power cord listed in the ad. But Iceco has been quick to resolve that. They issued a partial refund for the out-of-stock cover & will ship the 12ft power cord separately.

Paired with husband's battery box, I think it will be a nice upgrade from our cooler setup.

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Cool find and project!
Thank you!
Haha. Thanks!

T-minus 4 days until our next camping trip and we're rushing to get things done with the Land Cruiser & roof top tent.

Picking up where I left off: the brakes still didn't feel great after initial bleeding. So we tried again after driving around the neighborhood & that must've broken up a pocket of air. We got several small bubbles out of each side the next time around and the brakes feel much better now.

Husband picked up a second set of Yakima crossbars to help distribute the weight of the roof top tent across the gutter mounts. He also removed the factory roof rails to give more room/clearance. That left us with a bit of a conundrum: 5 out of the 8 factory nutserts pulled out of the roof. So our Wit's End hardware wasn't quite going to cut it. We didn't feel like messing with dropping the headliner, so husband found a neat temporary (might end up being semi-permanent) trick on here. He picked up some wide button head Christmas tree clips & used clear RTV silicone to seal them over the open holes in the roof. It's not the prettiest, but it works for now. Down the road I would like to remove the plastic ribbed pieces & weld up all the holes.

While that project dried, he also swapped in a set of OME stock height HD rear springs and greased the u-joints on the driveshafts. We also snagged the last set of Energy Suspension front sway bar bushings in black from RockAuto, so those replaced the blown out stock bushings. No more saggy butt when loaded down, it leans less, and it is less clunky when going in/out of park & drive. Quit the improvement!

Since then we've been driving it every opportunity we can to work out any other bugs that pop up. And fortunately the original(?) passenger front window motor finally died last weekend - all the way down and right before a storm, of course. This was the only one we hadn't previously replaced. So the Land Cruiser sat in the garage until the new Aisin motor/regulator combo arrived & was swapped in.

Last up was an oil change & a slight adjustment of the throttle cable and transmission kickdown cable. Previously the idle would maintain around 700rpms until you sat through a light cycle and it would slowly drop to 500rpms. This seems to have resolved that issue and slightly bumped the idle up to 750rpms. The transmission also appears to be holding 2nd gear longer when it downshifts on those steep long inclines. Rather than downshifting two gears, slipping, and immediately shifting back up to 3rd, it seems to stay in 2nd for a useful period of time before shifting up.

That's all I've got for now. I was gone on a work trip last week, so the rooftop tent is currently drying after touching up some spots with Seam Grip & waterproofing it with Nikwax Solarproof. Fingers crossed it keeps us dry this next week.

Edit: I forgot to add that we got a matching Sequoia wheel & got our spare tire mounted. We also sourced the missing components from the factory tool kit (thanks, Alfredo!) and now have the spare mounted in the factory location. Woohoo!

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Bonus pic: a friend of ours just picked up this imported HZJ70 a few weeks ago. He should be bringing it to the cabin on Memorial Day weekend. So we're excited to see it in person.

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The weather forecast called for rain to move in last night, so we called in a few friends to help get the Roofnest back on the LC. Thankful to have awesome friends who can stop by with short notice.

Husband snagged the awning from the Jeep and got it mounted up today. He also noted that the tent has fully dried/cured & stayed dry during the rain last night.

A few more pics. Hopefully the next set I upload will be in the woods.

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Last weekend's camping trip went well. It served as our test run for the rooftop tent, fridge, & "redneck" battery box. And everything went smoothly.

We were able to get the Land Cruiser in at the local exhaust shop for some much-needed work. They replaced the muffler that was rusting from the inside out, sealed up a few holes, installed new hangers & realigned the exhaust. No more rattle trap Land Cruiser.

Husband had previously bought a battery box with DC & USB ports when it was on sale from Napa. The plan was to use it as our makeshift power station using an extra car battery until we picked up a Jackery or Bluetti. He also found that an old inverter box fit perfectly in the gap on top. So after wiring up a few things, we had a working power station (temporarily) borrowing our Z's battery & the inverter. This worked well to power the Iceco fridge & kept it at a solid 38* over the weekend. The battery still had 12.2V by time we got home late Sunday afternoon.

It rained a lot last week, so our plans included a bit of waterfall hunting in the Ozarks before settling in to camp on a nearby private property. We led some friends on the route to Lost Valley to hike the trail back into the cave, stopped at Low Gap Cafe for lunch (highly recommended!), visited Twin Falls near Camp Orr, and closed out the day with a hike to the naturally formed "bath tub" and waterfall on the private property.

Temps got down below 40* Saturday night, but we stayed cozy in the Roofnest with our trusty Nemo setup: x2 Cosmo insulated sleeping pads and a Tango Duo slip cover & down comforter. The area we were parked on had a slight slope, but we were able to level the rig out with a set of Tri-Lynx leveling blocks made for RVs.

The Iceco fridge was probably one of our favorite additions. We've car camped & done cross country road trips using a cooler & ice over the last 10+. But things ultimately ended up soggy, made a mess, or sometimes went bad before we could eat them. The fridge kept our food & drinks dry, didn't require upkeep, and used a minimal charge on Eco mode.

Our plan is to get the parts to mount a second battery in the engine bay - I've got them in my cart for the next Partsouq order - and set up a battery controller to power the fridge or any other accessories. Husband also wants to mount a flexible solar panel to the hood to provide a charge to the second battery. A friend did this using the Lensun Solar kit for his 3rd gen 4Runner and, while it's not the best setup with the heat & panel angle, it's done the trick without burdening his alternator. With the 3FE's 80A/90A alternator option, and ours likely on borrowed time, I think it would be more help than harm as well.

Lastly, I'll address the elephant in the room. The 3FE is slow. We knew this before driving it based on the numbers and jokes: 155hp (when new) and pushing 5000lbs with 33s, 160lbs on the roof, along with us and our gear. We laughed at the experience on our trips to the cabin. But going 30mph in first gear and losing speed on one of the steepest paved sections in the state? Oof. That was a tough realization of just how slow it can be. And this is at <2000' elevation. Fortunately we warned everyone in our group and made room where we could to let other (faster) traffic pass. Building speed beforehand was key. But unfortunately is not always an option when it involves tight corners.

Which brings on the next thought: engine braking with 8.1:1 compression is not great on a downhill 11% grade. We just refreshed the front brakes, which helped. But now we're wondering if upgrading to the FZJ brake setup for the front & rear should be considered down the road. Food for thought.

A few pics:

The "redneck" battery box
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Hogshead natural "bathtub" formation
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Hogshead waterfall and friend for scale
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Our camp for the night
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It rained a lot last week, so our plans included a bit of waterfall hunting in the Ozarks before settling in to camp on a nearby private property. We led some friends on the route to Lost Valley to hike the trail back into the cave, stopped at Low Gap Cafe for lunch (highly recommended!), visited Twin Falls near Camp Orr, and closed out the day with a hike to the naturally formed "bath tub" and waterfall on the private property.
First visited this area in the mid-1970s before it became popular. Would drive a Honda Civic down to the Kyle's Landing area and hike up Indian Creek as far as possible.
 
First visited this area in the mid-1970s before it became popular. Would drive a Honda Civic down to the Kyle's Landing area and hike up Indian Creek as far as possible.
That's awesome.

I grew up visiting the area in the 90s and have loved it since. The Buffalo River and surrounding national forest is a big reason why we're still in this part of the state.
 
Mid-week update.

Got another order of parts coming from Partsouq soon. We've noticed the fuel gauge seems off at times, which prompted the purchase. But I got an email shortly after ordering saying that the fuel sending unit is back out of stock. Oh well. Fingers crossed the rest comes through:

Rear window seal
Oil pressure sending unit
Distributor cap gasket
Radiator cap
Clamp, set plate, and hardware for 2 battery boxes

I also ordered an FZJ battery box from Serra Toyota. I'm disappointed to see that they have dropped their detailed online parts database in an attempt to streamline the site. But it's not unexpected. It's currently a mess with 502 errors, so I'm hoping my order goes through properly. I want to get our dual battery setup in and ready for future trips.

We've got one more thing that we'll hopefully be picking up tomorrow. So I'll update once that is in our possession & installed.

I'll leave you all with one more pic from this weekend. A friend caught us unaware while setting up camp. I thought the framing of the picture looked cool.

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Hello, Monday. We had a busy weekend.

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Husband got a message on FB from a shop manager asking if we needed anything for the Land Cruiser. After some discussion, we ordered an ARB winch bumper and drove to Conway on Friday afternoon to get it. Our buddy joined us in his new Ranger Tremor.

We were in a bit of a hurry, so we took the interstate on the way down. That section was 150+ miles and is the most we've traveled on the interstate. Fortunately the Land Cruiser took it in stride. Although it spent a lot of time in 3rd gear climbing inclines while keeping up with traffic around 75mph. It also averaged right around 12mpg. So I think we'll try to stick to the slow & steady (65mph) method in the future - when we're not in a rush - to see if it can do better.

We arrived at US Truck Accessories in Conway and the owner, Josh, was super nice & helpful. He guided us to the back of the shop to unwrap & inspect the bumper. Once it was given the green light, he told us to pull the Land Cruiser around and jumped right in to help install it. Husband had previously removed the old bent bumper, so the new one went on and was ready to go in 15 minutes. I highly recommend anyone nearby to give Josh a call if you need any aftermarket parts or accessories for your vehicle. He is an authorized dealer for ARB, Ironman 4x4, and several other parts companies.

After leaving there we headed toward our campsite at the JFK campground near Greers Ferry. Our spot had water & electric hookups, but was otherwise nicely tucked back in the trees behind the Little Red River. The river is stocked with trout from the nearby hatchery and appeared to have good opportunities for fishing as well.

The next morning we headed out, opting for more slow-going backroads versus the interstate. We got caught up in some dense fog that slowed us to 25mph for a portion of the drive, but that cleared up once we reached the infamous Who-Da-Thought-It store in Sand Gap to refuel. From there, it was smooth sailing with clear skies on the way home.

By the time we got home the trip odometer was over showing over 2000 miles since we got this thing back on the road.

A few more pics:

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Husband took advantage of a slow work afternoon and knocked out the snorkel install yesterday. He picked up a Safari knock-off snorkel on sale a month ago and has been eager to install it. After our last wet trip, I'm not as against the idea of it as I originally was.

The only hiccup he had during install was the original - and very brittle - throttle body hose "exploded" while being moved. So we're now waiting on a replacement for that and the lower hose to the airbox from City Racer LLC. He also cleaned out the dirt & debris from the air box's "tuna can".

My Partsouq & Serra Toyota orders also arrived. So I'm hoping we can make some time around Mother's Day activities to get everything installed.

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Husband took advantage of a slow work afternoon and knocked out the snorkel install yesterday. He picked up a Safari snorkel on sale a month ago and has been eager to install it. After our last wet trip to Mirkwood, I'm not as against the idea of it as I originally was.

The only hiccup he had during install was the original - and very brittle - throttle body hose "exploded" while being moved. So we're now waiting on a replacement for that and the lower hose to the airbox from City Racer LLC. He also cleaned out the dirt & debris from the air box's "tuna can".

My Partsouq & Serra Toyota orders also arrived. So I'm hoping we can make some time around Mother's Day activities to get everything installed.

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What's this last pic? what is that in your hand?
 
What's this last pic? what is that in your hand?
That's the tuna can on the bottom of the air cleaner housing.

Remove the clips, drop it off and dump the debris. It is a reservoir for the heavier items that get sucked into the air cleaner.

You need to keep it clean.
 
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What's this last pic? what is that in your hand?

That's the tuna can on the bottom of the air cleaner housing.

Remove the clips, drop it off and dump the debris. It is a reservoir for the heavier items that get sucked into the air cleaner.

You need to keep it clean.
Correct. That was debris from the air cleaner housing.

We're going back to the cabin this next weekend. It's rained pretty steadily over the past few weeks. So I'm glad we got the snorkel on. Husband has also been busy piecing together his new winch setup to act as a backup.

A friend of ours recently bought a Warn VR Evo 12S winch for his 70 series & then realized that he needed a 24-volt version. So he cut us a deal on the 12-volt version he had purchased. Installing that with the roller fairlead we picked up last week requires a few extra parts: polyurethane rollers, spacers, and different hardware. So we're waiting for those pieces to be delivered and get everything installed.

This weekend was mostly spent working on other vehicles: our buddy with the Ranger Tremor came by for help installing his hidden winch. And another friend stopped by to help, so we got to check out his new Bronco. Looks like a fun rig.

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Winch is now installed. I came home to the guys winding it up under tension using the Jeep as an anchor. Quite the sight.

Readers with a keen eye may notice we got the spare battery box installed. I have the clamp/bar set ready and now just need another battery. We'll probably pick up another Duracell AGM from Sam's Club in the coming weeks.

One neat find: the bolts used to mount the FZJ battery box were already in the engine bay. So install consisted of unbolting the remaining assorted brackets, dropping the box in, and bolting it all down together.

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Memorial weekend came to an end too soon. We had a great time at the cabin & enjoyed doing some roadwork to get there. The rain & high winds last month flooded out much of the road: moving large rocks, downing trees, and even caused one water break to fail. But we were prepared with shovels, picks, chainsaws, a few winches, and several eager hands. Our usual hour on the trail took four hours with all the cleanup needed.

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