'78 FJ40 "Build"

[twonamesjames]

I recently inherited a 1978 FJ40 from my grandparents. My grandfather is still very much in love with it, but they've both starting to have health issues and need to downsize, so now I am the proud owner of the "Green Machine". It was bought by my great uncle either new or from a very short lived first owner, no one quite remembers anymore, but regardless it's been in the family for nearly its entire existence (no PO to curse here...). I'm looking forward to carrying the torch for while!

Circa 2021 it needed a top end rebuild and I was looking for a project, so I fixed it up in return for eventual ownership. I ended up having the camshaft repaired and reground with a more aggressive profile by Delta Camshafts, as well as replacing the lifters and pushrods, with the assumption that some day I will likely have to do a "real" rebuild, because there were some serious chunks of valve train in the oil pan (images of the carnage below...). That being said, it's been driving around for 3 or so years. The 2F is tough after all.

I say "build" in the title because I'm not really looking to "build" it into anything, I'm going to try to keep it stock and/or period correct for the most, just needs some fixing. The biggest challenge is going to be getting the smog equipment back together, as it was desmogged while it was in Oregon.

 

[twonamesjames]

First step's first, got to get it back to California! It was an Oregon truck originally, but it's moved back and forth with family every few decades. First 100 miles or so were nerve wracking. For the past 10 years it had solely been driven around town, and I had picked a stormy weekend to drive it down. I wasn't entirely sure we'd make the 450 mile journey back. Decided to take The Back Roads, because fighting semi's going on I-5 sounds like a nightmare.

Stopped to lock in the hubs!

Considered camping, but the empty campground and signs warning of a mountain lion that was regularly being spotted in the area made me reconsider.

Much has been made of how terrible the lights and wipers on 40s are, but they served me well!

 

[pb4ugo]

Beautiful 40 and story. You got something special. That should clean up nicely. You can probably find stuff in the classified section. You can also put a wanted ad in there too.

 

[twonamesjames]

Beautiful 40 and story. You got something special. That should clean up nicely. You can probably find stuff in the classified section. You can also put a wanted ad in there too.

Mud members have been quite helpful on the classifieds. I've already picked up a few things, and I think I know where to get everything else.

 

[pbgbottle]

Very lucky ,nice machine. Take care of that family treasure. Love it.

 

[Suntreemcanic]

Did that FJ40 come from Black butte Ranch near Bend Oregon? My son worked for a tow company in the summer while going to college around 2000 and he told me of a green FJ40 that he went out there and put a new battery in it. I remember him telling me how perfect it was. Just like yours, you are very lucky.

 

[cruisermatt]

that looks like a nice 40. Put some tires on it - those AT's are at least 15 years old.

 

[twonamesjames]

Did that FJ40 come from Black butte Ranch near Bend Oregon? My son worked for a tow company in the summer while going to college around 2000 and he told me of a green FJ40 that he went out there and put a new battery in it. I remember him telling me how perfect it was. Just like yours, you are very lucky.

It's quite possible, I'll have to ask the family next time I see them. That would be a fun story

 

[twonamesjames]

that looks like a nice 40. Put some tires on it - those AT's are at least 15 years old.

Oh yeah, new tires are on the list. It'll be in the garage for a while it's getting refreshed, but as soon as it's back on the road it's getting new tires.

 

[twonamesjames]

Grabbed a box of emissions parts from local mud member @kevos37 for a great price, and an emissions computer from @Engineer8000.

Still need a few bits here and there, but a good start.

 

[greenEFSI]

Awesome 40 and great story as well. I recently re-installed all the smog equipment and passed ca smog in my 78. Feel free to ask any questions! Can you post a pic of the emissions decal under the hood?

 

[twonamesjames]

Awesome 40 and great story as well. I recently re-installed all the smog equipment and passed ca smog in my 78. Feel free to ask any questions! Can you post a pic of the emissions decal under the hood?

Here's the decal:

 

[greenEFSI]

Lucky for you that is a Federal spec decal. So, you don't need the CA specific parts, like the unobtanium thermal reactor exhaust manifold, but you will need a federal spec exhaust manifold (if it isn't on there already). Under the third line AI + EGR tells the smog tech to look for the air injection and egr equipment. I see that you have those parts in the box, but the abv is rotted out and you will need another one. I have extra hi-temp silicone hose and clamps for the areas circled in red. Many members helped me sort out my emissions system and I'll pay it forward by sending them to you (if you'd like).

Do you have any photos of any emissions components that may still be under the hood? VSV/BSV valves, air pump, carb etc.

 

[twonamesjames]

Lucky for you that is a Federal spec decal. So, you don't need the CA specific parts, like the unobtanium thermal reactor exhaust manifold, but you will need a federal spec exhaust manifold (if it isn't on there already). Under the third line AI + EGR tells the smog tech to look for the air injection and egr equipment. I see that you have those parts in the box, but the abv is rotted out and you will need another one. I have extra hi-temp silicone hose and clamps for the areas circled in red. Many members helped me sort out my emissions system and I'll pay it forward by sending them to you (if you'd like).

Do you have any photos of any emissions components that may still be under the hood? VSV/BSV valves, air pump, carb etc.

View attachment 3828094

View attachment 3828097

Yeah, I was relieved to know I had a federal rig.

I'd be happy to get my hands those silicon bits. I've actually gotten some guff from a smog tech about silicon lines, but as far as I've read they're perfectly legal...

I'm trying to track down another ABV, got that one for free (mostly for the plastic hose guide). I've got a smog pump, but I might need another one, this one has a small stiff spot. I'm also still looking for the VCV and the associated bracket. I see there's a reproduction, but I'd prefer the original. Other than those I've got all the major parts (or they're on the way).

That's one clean engine bay. Are the vacuum line
guides readily available?

 

[greenEFSI]

The silicone is just a small union for the main part which is the metal pipe. If you delete the metal pipe and run a rubber hose the heat from the egr will cook it.

The secondary air pump could be saveable. You’ll need to pop it open and see what’s bound up. Small bearings on the carbon vanes and the front bearing are replaceable. The rear bearing is nla and I haven’t heard of anyone finding a replacement. I just greased that one good and put it back together.

I’ll send you a message with vacuum routing stuff so we don’t clutter this thread up

 

[Andrew S]

I'd love to see the "clutter" 1978 vacuum routing stuff, if you're both willing to share it here. I have a lot of spaghetti to sort out on my own 1978...

 

[greenEFSI]

I'd love to see the "clutter" 1978 vacuum routing stuff, if you're both willing to share it here. I have a lot of spaghetti to sort out on my own 1978...

I'll send you a message with some info as well.