79fj40 on 80 chassis! (1 Viewer)

[plfj40]

Now before the frond end is totally assembled I wanted to take care of the clicking noise coming from engine when i bought the 80. After talking to friends with fj80 s and checking the forums I figured that it was the power steering pump gear which is a common problem on the 4.5 . Took the pump out and checked the gear. Looks good. Hmmm. Looked at the idler gear and there it was. Damaged tooth.
Looks like a piece of metal fell between the crankshaft gear and idler gear and damaged both.

 

[plfj40]

So now what?
In order to replace the gears I need to remove timing cover.
In order to remove timing cover the oil pan need to be removed first. Also everyone said that the head needs to come off . Will see. Removed the 2 piece oil pan and. Valve cover.
Then I removed front timing cover . Didn’t need to remove cylinder head .

 

[plfj40]

Looked online as called the dealership parts . They wanted over $200 for just one gear. That’s crazy !!!!
The other gears were about $75 each
After looking online I found brand new parts for sale on eBay. It was half price. Hmmm. Looked sketchy. But i always use PayPal on eBay so I had no worries. Ordered parts thinking that it would be some Chinese crap.
They showed up couple of weeks later all the way from Dubai. Opened the box and there’s the gear. Toyota original gears for half the price of dealership.

 

[plfj40]

Got new timing chain kit and replaced all plastic guides . Got new thermostat and water pump . All new seals for crankshaft and oil pan and valve cover. They were leaking anyway already.
Installed new gear on pump

 

[plfj40]

Painted the front bib with and bezel. Used black Berliner on back floor. After looking at it decided to painted red like the rest.

 

[plfj40]

Pulled out of the garage to cleanup the place.

 

[plfj40]

Removed complete harness from the 80. Time to figure out what can be removed from it.

 

[plfj40]

time to stuff this in

 

[plfj40]

Taking a break from the 40 to swap my old fj40 disk brake axles into my brothers 71 fj55

 

[plfj40]

Fj80 Brake switch fits in the original 40 spot perfectly

 

[plfj40]

Got most of wiring done.

 

[plfj40]

Got the fan attached and in truck
Wired power and relay

 

[ceylonfj40nut]

What fan is that? Had one similar but it did not work. Is that PWM brushless type? If not it will not keep up at least here in TX

 

[plfj40]

What fan is that? Had one similar but it did not work. Is that PWM brushless type? If not it will not keep up at least here in TX

It’s flex a lite 16 inch I think. It works well so far. Had the truck out it PA for coal mine cruiser classic and it was very hot all week. No issues.

 

[MountaineerLC]

Awesome build!

 

[plfj40]

Ok the big moment is here, time for some fuel
Couple of cranks and it’s Alive!

 

[plfj40]

Replaced old intake hose with Amazon special $20

 

[plfj40]

Gas tank in.

 

[plfj40]

Shortening the stock rear drive shaft by 8 inches. It’s a temporary setup to get the 40 out of the garage and test drive it.

 

[plfj40]

Pulled out of garage and the 40 Had no power. I forgot that the fj80 is awd and without front driveshaft installed it was sending most of power to the front .
Luckily Toyota gives u the plug that’s tucked away in wire harness for a manual switch to lock the Tcase in 4wd mode.
Used the hazard button to activate the locker