77 FJ40 - Slow & Steady Rebuild

KingAir Driver

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Spokane, WA
Hey Everyone,

I've been scanning this site for awhile, both at home and abroad just waiting for an FJ40 to drop some dough on and throw in my garage. I finally found a one owner, 59,000 mile, 1977 (11/76 production) FJ40 in Freeborn Red. The previous owner had used it sparingly over the past couple years with a snow plow attached, but it mostly sat in the out-building. Typical rust in the rear sill area and when I got it home and pulled the factory floor mat, some rust holes between the trans tunnel and drivers floor pan, but the passenger side is mint, as well as the rear bed. The front doors are slightly bent at the top from a garage roof cave in from heavy snow, but the roof panel was replaced. It took a little to start up and drive, but I had it flat-bed towed home to be on the safe side.

Plans for the immediate future are fuel system overhaul with new lines, filter, and carb overhaul (been watching Pinheads videos and have a Hygrade 791B kit on the way). Partial de-smog to get some of the clutter out of the engine bay, Cooling system overhaul with new hoses and water pump (leaking at the back seal), and then tear into the brakes and steering components since there is a lot of slop in the steering wheel, then when money permits, go OME suspension. Just trying to make it a safe driver before tearing in the body work.

Since you all love pics, here are a few:

FJ40_11.jpg


FJ40_12.jpg


FJ40_13.jpg

Port options sticker on the inside of the Glove Box door, anyone seen this before?

FJ40_14.jpg


Finally home in the garage, in fine company...

FJ40_15.jpg
 
Joined
Sep 1, 2014
Messages
551
Location
Calgary, Alberta
Congrats on the purchase and welcome to mud - my '77 came with 53k on it, or at least it had that when the speedometer crapped out - but your is in way better condition, should be a fun build,
Cheers!
 

78fj40mg

TLCA #23510
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Sep 13, 2008
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forum.ih8mud.com
Welcome to MUD!
Nice rig, looks like an easy restoration, great find!

My 40 keeps good company as well just like yours.
 

TheHardWay

Ain't as easy as it looks
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Good score, and thanks for anticipating our need for Cruiser porn:flipoff2:
 
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Alva, Fl.
A little wash 'n wax and drive it! It'll tell you what it needs-
Very nice!!
 

KingAir Driver

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Spokane, WA
Thanks everyone! All your build threads have been an inspiration! Already started the tear down last night! Carb removed and removed passenger side seat and exposed down to the fuel tank and lines. Pics coming later.

GHalll : yes, he bubba'ed the alternator bracket to run a single wire alt to run the plow.

Sggoat : wish it was that easy! When I wiped the snow off, my towel came up red. Definitely no protection on there.
 

KingAir Driver

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So I guess not so slow and steady; Passenger side seat and tank cover removed for hose replacement, air cleaner assembly, carb, intake and exhaust manifolds removed and most of the air pump/egr system. Broke a stud on exhaust manifold where the EGR pipe attaches on the bottom (hopefully I can extract it), other than that no issues other than the air pump is stuck on the pivot joint and I can't get the bolt out yet.

Trying to get a good amount of stuff to blast at the auto hobby shop on base, they said they are using aluminum oxide, so hopefully that's not too aggressive.

Any thoughts? Air Cleaner, Manifolds, Valve Cover, Heat shields, skid plates, and rear bumpers to start?

Maybe this is why it was having issues starting? Lack of clean air?

Air Cleaner Box.jpg


This is definitely getting blasted and refurbed!

air cleaner box2.jpg


Pretty clean looking tank! You can see the rust on the driver's side floor-board! Arg...

IMG_1999.JPG


Here's the rest of the parts and engine bay progress.

9 Jan 16_1.jpg


9_Jan 16_1.jpg
 

thorslc1977

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Aug 14, 2012
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509
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Tehachapi Ca.
My Freeborn Red 77 had 2.3 miles on it when I picked it up in Las Vegas. Good luck on your build/restore. I have spent a lifetime (38YRS) enjoying mine and I still get a smile on my face when I drive it. I will only give it up when they pry my corpse out of it according to my kids.
 

KingAir Driver

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Got around to replacing all the emissions lines behind the gas tank and also the rusted out fuel filler neck, hose, and gas cap. I've read the bad reviews on the CCOT tank hose and filler neck, so we'll see what happens! Next up get the lines going to the fuel pump/filter and charcoal canister. Received my Hygrade Carb Kit and picked up a can of Berryman's Carb Dip to knock that out this week.

Waiting for the weather to warm up so I can blast and spray some parts, or check with the local powder coater for pricing.


Note to self, don't put 10 gallons of gas in the tank when you know you're going to be working on it. You can also see the years of dust being wiped away and potential rust areas!

Fuel Filler1.jpg
 
Joined
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Kuwait
I have a 82 and looking for a place that sells fuel lines online and other items related to the fuel system.

I found a fuel evaporator online that I bought used as a new one is NLA as I recall.

Any pointers ?
 

KingAir Driver

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I just picked up bulk Gates Barricade fuel hose from the local auto parts store in 5/16" inside diameter and 1/4" inside diameter. I did order off ebay the one 14mm braided fuel line from the tank to the filler neck. I used the search function a lot on here to get everything I needed.
 

KingAir Driver

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Carb re-build complete. Props to @Pin_Head for his outstanding videos! It took me awhile to figure out the linkage to make sure it was turning the right way, but overall it turned out pretty good.

Next up Cooling system refresh: Water pump, all OEM hoses and clamps, thermostat, etc! Also, tons of parts need painting or powdercoating. Stay tuned.


Pre Dip:

Pre Carb.jpg


Post Dip:

Completed Carb1.jpg
 
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KingAir Driver

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Continuing to chug along with the tear down and refresh. Got my exhaust manifold back from the local machine shop since I broke one of the EGR studs off and couldn't get it out. So they heli-coiled it along with 2 of the exhaust flange studs which I had them remove. I got all new studs from SOR. Need to figure out if I'm going to blast and paint it or go for some other coating.

Picked up another '77 wiring harness since mine was fried, thanks @GA Architect for the link. Now just need to clean it up and swap some connectors that were brittle/broken on the new one.

Drained the coolant from the radiator and removed the shroud/fan/pulley in anticipation of replacing the water pump and hoses. Dropped off a box of parts at the powder-coat shop... whew..

exhaust manifold.jpg


harnessxtwo.jpg


overview.jpg


And I'm confused about this one... I don't think the nut on the harmonic balancer is supposed to look like this? Thoughts anyone?

wtf.jpg
 

KingAir Driver

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Water pump and thermostat housing removal time. In hindsight, I should have drained the coolant out of the block drain prior to unbolting the water pump, live and learn I guess. At least I still had a tub underneath to kick into place. Looks like the PO decided RTV was a better gasket to use. The only issue I had was separating the thermostat housing, I couldn't get the bolts to budge! So in one piece it came off. Now, I need to figure out how to separate them!!

Also here's a better picture of the claw nut.

WP removal.jpg


bucketoparts.jpg


clawnut.jpg
 
Joined
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Denver CO
Post up your frame number and engine serial number if you wouldn't mind. My 10/76 was freeborn red too.
 

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