77 FJ40 - Slow & Steady Rebuild

[KingAir Driver]

@wscbill , here's a pic of the tool bag and parts that came in it. Based on your diagram, the bag looks correct, but the red clip holding the wrenches is for a later model. Looks like it's missing a few things.

 

[KingAir Driver]

The carnage that is the right front brake caliper and pads! Tried to get the Allen head bolts out of the Warn hub face, no dice! Shot with PB blaster and waiting. Headed out to pick up my rims from powder coat, new caliper from Napa, and a 54mm hub socket from 4x4 parts place.

 

[DSB345]

Engine by looks awesome!

 

[KingAir Driver]

Just picked up my rims! (#5 in the back seat)

 

[78fj40mg]

Just picked up my rims! (#5 in the back seat)

View attachment 1225170

Beautiful OEM rims! I did the same with mine.

 

[wscbill]

@wscbill , here's a pic of the tool bag and parts that came in it. Based on your diagram, the bag looks correct, but the red clip holding the wrenches is for a later model. Looks like it's missing a few things.

View attachment 1225114

Nice collection of tools. Those are all FJ40 pieces except for the L-shaped handle with the flat end, which is from a FJ60/62 kit. The jack is from 1972-76, still has the original caution sticker. The 77 jack has a wide neck flange. The missing tools are fairly common, so it's possible to complete the kit without spending a fortune. For me, the most difficult piece to find is the plastic 2-wrench clip either red or yellow.

 

[KingAir Driver]

@wscbill , could it be that since the production date is 11/76 it could be the original jack? Are you talking about the large L shaped yellow handle or the smaller piece?

 

[wscbill]

@wscbill , could it be that since the production date is 11/76 it could be the original jack? Are you talking about the large L shaped yellow handle or the smaller piece?

Doubt that it is original to your FJ40. treerootCO and I examined several of the wide neck flange jacks for the latest jack reference write-up. The earliest of these was dated 9/76 (code 6I), which confirmed they were the type of jack used with model year 1977.

The 6I is a date code on the top rim of the jack. The year is numeric, month is alpha. See what the code is on your jack. I'm guessing it is much earlier than your FJ40 production date of 11/76.

The large L-shaped yellow handle is for the jack. The smaller piece, between the wrench set and tool bag in the photo is the spark plug wrench handle from FJ60/62 kits.

 

[KingAir Driver]

@wscbill , good info! I did find the Toyota lugnut wrench hiding in some other things. So I cleaned off the top of the jack and it's a 6 E.

 

[KingAir Driver]

PB Blaster is awesome! Got the hub front off, the hub base nuts, then many swear words trying to get the snap ring off. Errr! Finally got the rotor and hub assembly off, took some more PB a BFG and a pry bar to separate, but got it done! Now, as I clean 39 years of built up grease and dirt off the knuckle, I find myself in the dilemma, do a rebuild now or later? I'm leaning towards now, because I don't want to pull this stuff apart again, but I'm leaving in 3 weeks for a couple months and don't want to get too far into something. Or knock out one side and save the pain for when I get back to do the other!

 

[wscbill]

@wscbill , good info! I did find the Toyota lugnut wrench hiding in some other things. So I cleaned off the top of the jack and it's a 6 E.

View attachment 1225393

That's interesting. We've been looking to find where the changeover was from the narrow to wide neck flange. We found a narrow flange 6B jack (Feb 76), now there's yours 6E (May 76). We also don't know the relationship between the jack date and vehicle production date, within 1-2 months, within several months, or what. Given the date of your jack, you could certainly make the argument that it is original to your 40. Maybe the original owner could say for certain.

This @treerootCO posting in the jack reference thread highlights a jack dated 5I (Sep 75) that is original to a May of 76 FJ40, an 8 month difference. Your jack is closer at 6E (May 76) with a production date of Nov of 76, a 6 month difference.

 

[KingAir Driver]

Decided to add a little bling to the rear door. To go along with the powder coated license plate frame I ordered new OEM light shields and lights. (I know sill and door rust!)

Also received my knuckle rebuild and bearing kit in the mail today from TORFAB, supporting Washington businesses! Ordered yesterday, and on my doorstep today! That's quick! The kit looks really good with Koyo wheel bearings.

I popped the fill cap off the knuckle to see what the inside grease looked like, and it was good. I cleaned the grime and 39 years of gunk off of them and I'll see what happens. I'm just going to replace the wheel bearings, rotors, front hoses, pads and calipers and save the entire knuckle rebuild until I get back if it is indeed leaking.

Pics as always.

 

[KingAir Driver]

New BFG 33x10.5x15 to go on the OEM rims. Black side out. Amazed that all 5 fit in the back of my wife's X5.

 

[78fj40mg]

Congrats very nice shoes for your 40! Are you doing the hub caps too?

I did the same for my cruiser last year.

 

[KingAir Driver]

@78fj40mg , I will do the hub caps once I get everything situated, good thing they are still readily available. Your thread is a great reference and your pic of black wall out sealed the deal!

How much grease did you pack in the hub? There was about 1/2" thick in between the wheel bearings on removal, but I can't find it in the FSM.

 

[78fj40mg]

@beno will give you a great price on OEM hub caps. A 1/2" layer is just right, you could add more later if need be through the grease plug located on top of the knuckle, I added a grease fittings to make it easier for future greasing of the knuckles.

 

[KingAir Driver]

Finished up the passenger side brakes. Napa reman caliper, raybestos brake rotor, bosch pads ,OEM brake hose and Koyo bearings. Moved onto the drivers side and should have that finished up in the next few days. Then bleed the brakes and put the new rims and tires on and finally ready to test drive! It's been 3 months!

 

[78fj40mg]

Beautiful work! Boy you move quickly with the rebuild process!

 

[KingAir Driver]

@78fj40mg , thanks! Just trying to get it to finished state before I leave for a few months on Sunday. I would have cleaned up and painted the hubs and other parts, just no time! And wouldn't you know it's snowing in Spokane!

 

[78fj40mg]

Snow in March is not unusual for WA, we are snow less here in the PNW but March is not over yet. Keep up the great work and pics!