Builds 79 FJ 40 Rebuild

[Stevens79FJ40]

It's not and efi, so you don't have high pressure etc. I bet you are fine. and if not - braise it. I used soapy water with pressure test and looked for bubbles.

I took the tank out 2 years ago so I’m not sure on working space with the tub and frame. I’m going to use an engine lift to put the body back on. Was thinking about securing the tank before the tub is in position. Any suggestions?

 

[Stevens79FJ40]

Also - I don't think there is a wrong answer to put on tank then the body, or body then the tank.

The biggest pro I see having just installed my tank - the cross member - have to angle the tank to get around the cramped space if tank goes on second - Setting all straight down on the frame with tank pre/installed may be easier.

if you have tub on rotisserie (or other way to invert), I would say tank first.

It is awkward and takes 2 people (unless you have good things to brace tank while you get straps on). if you can't flip the body somehow and install tank. if you don't have a lift - even more awkward on your back.

The difficulty I encountered is that I could not install the straps in the pin locations first, let them hang, and secure the other side after tank lifted into place - didn't work that way for me. Strap would not drop all the way down to provide enough for tank to slip in and up - so Rus and I put tank in place and one held tank and other then installed straps.

I don't know if clear.

Edited to complete last statement.

Thanks! Sorry i missed this before I asked for a suggestion. Yeah I think I’ll try to install the tank then get the body lined up! Thankfully it’s completely empty and doesn’t way a thing!

 

[OlYellr]

I would based on what I am seeing right now and remembering-

The cross member is why the straps won’t hang down.

Will be less time and hassle to install before -

And a case of beer and 5 friends, can lift the tub and place too

 

[psmbfuer]

Late to the party, but a lot of excellent work Steven. If you need help with that tank, I'm close enough to swing by many weekends. And excellent to have a project like this with your daughter - well done.

 

[Stevens79FJ40]

Late to the party, but a lot of excellent work Steven. If you need help with that tank, I'm close enough to swing by many weekends. And excellent to have a project like this with your daughter - well done.

Thanks so much! I’m going to barrow my neighbors cherry picker and install the tub next week! It’ll be nice to see my garage minus an exploded 40 . I wish I had put every nut and bolt in a nice labeled baggy. Next time wait no next time!!!! Lessons learned

 

[psmbfuer]

Sounds like a plan. I'm also very much with you regarding the exploded Cruiser syndrome. My shop is small and taking things apart is easy, but finding a location to store and organized the parts while keeping enough room to work is another matter. And bagging / labeling = good. I learned a long time ago to bag and label everything. If I could compete a Cruiser in a month, maybe it wouldn't be as important, but after one sits for a year or so, and the project takes a better part of a decade the boxes of bolt / parts get a little less familiar.

 

[Stevens79FJ40]

Sounds like a plan. I'm also very much with you regarding the exploded Cruiser syndrome. My shop is small and taking things apart it easy, but finding a location to store and organized the parts while keeping enough room to work is another matter. And bagging / labeling = good. I learned a long time ago to bag and label everything. If I could compete a Cruiser in a month, maybe it wouldn't be as important, but after one sits for a year or so, and the project takes a better part of a decade the boxes of bolt / parts get a little less familiar.

Exactly! I was so confident I’d know where everything went back to. I think I’m keeping my local Ace in busy solely by purchasing bolts

 

[Stevens79FJ40]

Finally got the tank in. Definitely helped tapping the skid plate to the tank. Nothing was lining up at first and I was worried this tank was just slightly larger than original. But after measuring everything it’s almost an exact match.

Not fun walking your freshly restored 45 year old FJ40 body across the garage floor on an engine host attached by ratchet straps. But the Mrs. Was a big help

Of course the leg of the hoist lined right up with the rear axle so I had to remove the tire, still fought the support jack.

Then come to find out a PO installed a rear brace on the tub and drilled the holes for the mounts in the most random locations. So I have to align the body, mark new holes, remove the body, drill the holes and re mount the tub .

Will it ever end?……

But at least I have half my garage back

P.S. I’m so worried about this OME suspension I bought off FB. I know everything is oriented correctly, installed correctly. But I feel the rear tires are super close to the front of the wheel well. Definitely more forward than centered. Is that an FJ thing?

 

[fireflyr]

Just for perspective, mine has an OME 4” lift. I measured from the edge of the door seam on the tub to the center of the hubcap and came up with 20”. Hope this helps.

 

[Stevens79FJ40]

Just for perspective, mine has an OME 4” lift. I measured from the edge of the door seam on the tub to the center of the hubcap and came up with 20”. Hope this helps. View attachment 3838682View attachment 3838683

Thank you! I’ll verify that measurement once everything is aligned. Big help!

 

[PidgeonGuggolo]

Wiper linkage

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How did you get them so shiny?

 

[Stevens79FJ40]

How did you get them so shiny?

Sanded and repainted

 

[Stevens79FJ40]

Ok having a little freak out moment.
Installed my transmission inspection cover, my new shift boots and knob’s, all excited tried shifting gears just for fun and it just floats in neutral.

No I don’t have the clutch cylinder installed just the slave cylinder and the clutch fork would not move
I removed the slave cylinder, clutch fork will move forward “beyond” its resting position or neutral location

But it seems like the clutch fork will not move as if you were to engage the clutch pedal….

I just got the body on
Really hoping I don’t have to remove it to then remove the transmission and inspect the clutch, throw out bearing etc.

I should be able to test the gears correct? I’m just stumped

 

[B y r o n]

Ok having a little freak out moment.
Installed my transmission inspection cover, my new shift boots and knob’s, all excited tried shifting gears just for fun and it just floats in neutral.

No I don’t have the clutch cylinder installed just the slave cylinder and the clutch fork would not move
I removed the slave cylinder, clutch fork will move forward “beyond” its resting position or neutral location

But it seems like the clutch fork will not move as if you were to engage the clutch pedal….

I just got the body on
Really hoping I don’t have to remove it to then remove the transmission and inspect the clutch, throw out bearing etc.

I should be able to test the gears correct? I’m just stumped

Need some clarification on the information you posted. "I don’t have the clutch cylinder installed just the slave cylinder", are you saying you mounted the slave but not the master?

"clutch fork will move forward “beyond” its resting position or neutral location

But it seems like the clutch fork will not move as if you were to engage the clutch pedal…." Moving the clutch lever forward means it is moving away from the pressure plate. Moving the clutch lever to the rear you won't be able to overcome the pressure plate.

If you cannot shift through the gears, without pressing on the clutch, you may need to bump the car with it in gear as there may be interference in the trans. The other option is that the shift lever was not installed with all the forks in the proper position.

 

[RevISK]

The other option is that the shift lever was not installed with all the forks in the proper position.

This happened to me recently.

 

[Stevens79FJ40]

This happened to me recently.

No hydraulics ATT still rebuilding the vehicle no slave/master

Yes I tried moving the fork towards the rear as to engage the pressure plate.

I thought the shift lever may not be installed clearly so I took it apart and reinstalled. Maybe I need to try it a third time.

i guess unless the clutch is engaged I cannot move out of neutral? I’m quite a ways from having the clutch ready to go

I just wanted to make sure nothing was misaligned, bound before I finish putting the 40 back together…

 

[RevISK]

No hydraulics ATT still rebuilding the vehicle no slave/master

Yes I tried moving the fork towards the rear as to engage the pressure plate.

I thought the shift lever may not be installed clearly so I took it apart and reinstalled. Maybe I need to try it a third time.

i guess unless the clutch is engaged I cannot move out of neutral? I’m quite a ways from having the clutch ready to go

I just wanted to make sure nothing was misaligned, bound before I finish putting the 40 back together…

If you pull the shifter out, what does it look like in there?

 

[Stevens79FJ40]

 

[fjc-man]

If you don’t have a functioning slave cylinder pushing on the throw out bearing ,depressing the pressure plate fingers, to unclamp the clutch disc the input shaft has no wiggle room for movement. That’s most likely the reason you can’t row through the shift pattern stationary.

 

[3_puppies]

View attachment 3844186

you need to use a prybar or similar to align the shift rails, the one at 6 oclock needs to move to the left and center with the rail at 12 oclock
make sure the wheels are chocked

you cannot move the clutch fork by hand it needs lots of pressure to depress the clutch springs