Builds 79 FJ 40 Rebuild

[Skreddy]

I’d see if you can run an in tank pump like the Tank, Inc one in that fuel pickup hole. When I had one apart before it looked like it’d work.

 

[Stevens79FJ40]

top left is the fuel line pickup assembly
bottom middle is for the fuel level sending unit

Thanks for the clarification

 

[Stevens79FJ40]

Now when it comes to taking the transmission out, as I move back I run into the crossmember. I read a few post about pulling it back and letting it drop but if much rather use the hoist and come up and out. The input shaft for the trans is still in the bell housing. I’m arias I’m going to pick/snap something. Is it just slow and steady tilt and lift?

 

[Stevens79FJ40]

Now when it comes to taking the transmission out, as I move back I run into the crossmember. I read a few post about pulling it back and letting it drop but if much rather use the hoist and come up and out. The input shaft for the trans is still in the bell housing. I’m arias I’m going to pick/snap something. Is it just slow and steady tilt and lift?

 

[pb4ugo]

I think most folks remove the rear motor mounts and drop the rear of the engine and trans to clear the crossmember.

 

[Stevens79FJ40]

Ok, what I found useful was to remove the mounting bolts, broke one. Going to need me bushings anyway.

Pull the trans away as much as possible and lift the engine with a floor jack and trans with hoist in unison until I could clear the cross member.

 

[3_puppies]

just be cautious of the fan and radiator clearance when lifting rear of engine or lowering rear of engine

 

[Stevens79FJ40]

Progress

 

[Stevens79FJ40]

Had I known, I would probably have never bought this thankfully I don’t need an inspection in PA. I’m doing my best here. I put some additional bracing at the body mount section where the frame begins to bend up over the axle. Plus the boxing players should help a lot. I mean, compared to what I started with, you could run a screwdriver through it.

 

[Stevens79FJ40]

Boxing plate

 

[OlYellr]

Great work!

I’m finding stress cracks in mine and just looking what lies ahead to reinforce. Again love your work.

If you are going to take off road any, since you are there, the rear leaf pin gets stress cracks. A triangular plate boxed in strengthens it.

 

[Stevens79FJ40]

Great work!

I’m finding stress cracks in mine and just looking what lies ahead to reinforce. Again love your work.

If you are going to take off road any, since you are there, the rear leaf pin gets stress cracks. A triangular plate boxed in strengthens it.

Thanks for the heads up. I was considering a plate on the inner frame walls where the boxing plate meets the original and replaced sections.

 

[OlYellr]

There is a boxing plate kit too for others facing this issue.

I updated the thread today with a link that goes to that kit.

Can post here too if -

 

[Stevens79FJ40]

There is a boxing plate kit too for others facing this issue.

I updated the thread today with a link that goes to that kit.

Can post here too if -

Thanks! I found mine off Etsy lol fit perfectly though. It did not come with the rear cross tube but…..

 

[Stevens79FJ40]

Frame FINALLY repaired and POR-15. Repaired I hope…..lol I started wire brushing the front bumper to prep for fairlead and D ring mount. Found an 1” thick pile of bondo guess I’ll paint and cover with a cool sticker

 

[Stevens79FJ40]

Frame is fully done now. Ceramic coated the exhaust manifold also. Might not last long but I like how it looks sitting there. Where it will probably continue sitting for another year

 

[Mr. Green]

Did you clean the rust off the header first or just coat over it? I need to do same this weekend.

 

[Stevens79FJ40]

Did you clean the rust off the header first or just coat over it? I need to do same this weekend.

I wire brushed, cleaned, rust reformed, high temp black, ceramic grey, high temp clear

 

[Stevens79FJ40]

Could anyone tell me what this plate is for on the water pump. I’m cleaning mine and am just confused by it.
I have a clutch fan and the oil cooler. Just making sure I have the correct water pump.

 

[OlYellr]

I don't claim to be correct - but I believe is if for a solid backing since the head and the block meet and it isn't perfect.

First image is the gasket on the block. Second is close-up (before rebuild) of the back plate and can see how head and block not perfectly aligned (looks better on phone than screen). and even on first can see where block and head meet not smooth vertical surface. My opinion

and