A New Lease on Life

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Joined
Nov 28, 2010
Threads
59
Messages
2,885
Location
Austin, TX
My first LandCruiser (FJ40) came courtesy of a 50-50 JV with my father back in 1985. I was one year out of college and still young enough to know it all when my dad and I passed a 40 on the side of the road in El Paso, Texas with a For Sale sign in the window. We’d always talked about getting a good four wheel drive to hunt out of, so we turned around to take a look. $2,800 later we drove it home, little did I know the joy this truck would bring me over the course of my adult life nor could I have imagined the incredible people that this truck would sew into my life through the years.

About a year ago my Mom started to talking about needing a new car. They had 3 vehicles at the time, all Toyotas or TYOTOTA's as pronounced in her southern drawl; a fairly new Prius, a Hylander and a 97 FZJ80 with the factory lockers. With Dad's health in decline and now no longer driving, Mom started talking about getting the 80 out of the driveway. She had thought about gifting it to a grandchild but she thought it needed a lot of maintenance. She told me that something bad was wrong with it, so on a trip out they 6 months or so ago I took it for a spin. The 80 started right up and purred, pulling away I could tell that there seemed to be plenty of life left in the power plant but the truck did exhibit heavy steering and I could really feel all 4 tires grabbing at the pavement as it turned. Brakes seemed ok but the suspension and tires were shot, and the font axles clicked pretty loudly with a slight vibration through the steering rack in turns at slow speeds.

My Dad's degree was in engineering but he'd gone to law school as soon as he graduated. Good move Jim, he may be the most mechanically un-inclined person I know so law school was a good move. Later in his career he'd represented Toyota which gave him the ability to buy vehicles at employee pricing, so he took advantage when they bought the 80. The truck has served them well through the years. Dad had driven the 80 for the last 15 years or so on his almost daily trips to Mexico to carry food, meds and clothes to those less fortunate and the 80 shows the wear of his driving skills in Mexico. Several months ago Mom told me that a mechanic that worked on it last had offered to buy it, it was then that I told her not to sell because I would take it. What was I thinking, I have the original 40 plus a 100 that we use at our cabin in Idaho, not to mention our two daily drivers. Memories are hard to let go of and I felt attached to the 80, besides how much fun would it be bring this baby back to life, real life? And so a new journey begins.
 
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Here she is upon arrival

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A couple of weeks ago I pulled the running boards and gave her a good bath and first wax in years

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Today I coaxed my wife into parking in the driveway for week or so. First up an appendectomy to remove the VC that I think was causing the bound driveline. I’ve got it torn apart and VC removed but I found a leak at the base of the housing for the speedo cable. I noticed that it rocked back and forth when I pulled the connector.

I received a knuckle rebuild kit from Cruiser Outfitters this week so I plan to tear my axle open and see what I find before ordering the parts for the speedo housing.

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The heavy stearing sounds like the lockers are engaged.

I’m starting by pulling the VC and will install a CDL switch. The center diff engages in low (light comes on) and the lockers seem to work as well.
 
Funny, my parents built a cabin in WVa. Pretty remote area. When I was in grad school they decided they wanted a 4wd. So, I picked out an FJ60 for them. Five years later, they take it to China. When they move home, they learn the best place to sell them is Nepal. FJ60 is packed on a train to Chengdu, China and then Tibet. My parents hire a driver/mechanic to drive with them over the Himalayas. Carburator jets need swapping out periodically. FJ60 is sold for $1,000 more than it cost new in Nashville.

Order goes out for FJ80 to meet them when they get back home. At 85, my dad drives it everyday around a retirement community when he occupies his days planting trees and getting rid of invasive plants.

Maintenance costs on both of these have been tiny.

Good luck with your project.
 
VC removal complete; Wow what a difference! Had a scare after assembly when I couldn’t get it to move, the A/TC light was on then I woke up and remembered I put the TC in neutral to rotate the drive line reinstalling the DS.

Drives like a new truck and the clicking birfs are gone! The DS is leaking badly, so they are up next.
 
With Christmas behind and having a flexible work schedule for the coming week, I finally got started on a birf job. I’ve never done one so I poured through all 23 pages of the birf thread in the FAQ, loaded up on supplies and started in this morning.

DS up first since it’s been hemorrhaging gear oil. First clue that I had a mess on my hands was the ‘condition’ of the gear oil, it was more like gear oil sludge ... I’d describe it as a carefully blended mix of grease and oil.

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Next pulling the dust cap was a PITA, someone RTV’d it on. Once off gear oil poured out. Once I had the spindle off there was no evidence that grease was ever present, anywhere. Bearings were oily but clear of grease and the cavity was wet but no sign that grease had ever been there.

When I tried to pull the birf it seamed to be stuck or hanging on something. After some more wrangling I finally got it to come free... just the birf. The axle shaft stayed in place. I wish I had taken a pic for prosperity sake but my hands were a mess so I sent the birf aside and pulled on the axle shaft and with a little work it came free. As I removed it I realized that the shaft was installed backwards, snap ring side towards the 3rd member and luckily the snap rings was still there.

So now I’m trying to figure out if I have anything to worry about. I don’t have to worry about a wear line on the axle where it should have ridden on the seal, it looks great. But what about having the snap ring end inserted into the 3rds side gears? Spindle has some wear, nothing I can feel with my fingers so should I run it or replace it? What about a birf that has unknown miles on the gear oil / grease mix?

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Spindle looks really worn down near the flange though. I dont even have an 80 but I'd probably replace that thing. What was wearing in that spot?

My first time doing this job but I’d have to say the inner wheel bearing rides there
 
Next pulling the dust cap was a PITA, someone RTV’d it on. Once off gear oil poured out. Once I had the spindle off there was no evidence that grease was ever present, anywhere. Bearings were oily but clear of grease and the cavity was wet but no sign that grease had ever been there.

When I tried to pull the birf it seamed to be stuck or hanging on something. After some more wrangling I finally got it to come free... just the birf. The axle shaft stayed in place. I wish I had taken a pic for prosperity sake but my hands were a mess so I sent the birf aside and pulled on the axle shaft and with a little work it came free. As I removed it I realized that the shaft was installed backwards, snap ring side towards the 3rd member and luckily the snap rings was still there.

So now I’m trying to figure out if I have anything to worry about. I don’t have to worry about a wear line on the axle where it should have ridden on the seal, it looks great. But what about having the snap ring end inserted into the 3rds side gears? Spindle has some wear, nothing I can feel with my fingers so should I run it or replace it? What about a birf that has unknown miles on the gear oil / grease mix?

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How about wider shot of the spindle?

The seal surface seems to have a lot of wear and is in need of some emery cloth to clean up the sealing surface and remove the burrs on the edge.

It appears to have wear, but not horrible.

Obviously, the wheel bearings have been run loose a LOT! I hope you included new bearings and races in your rebuild kit.

Since this had "heavy steering", make sure the Birf cages are assembled properly. Obviously someone who didn't know what they are doing has been in there and very likely could have jacked up the birfs. Search the threads about Birf Cage and look for proper orientation from @cruiserdan .

Good Luck!
 
How about wider shot of the spindle?

The seal surface seems to have a lot of wear and is in need of some emery cloth to clean up the sealing surface and remove the burrs on the edge.

It appears to have wear, but not horrible.

Obviously, the wheel bearings have been run loose a LOT! I hope you included new bearings and races in your rebuild kit.

Since this had "heavy steering", make sure the Birf cages are assembled properly. Obviously someone who didn't know what they are doing has been in there and very likely could have jacked up the birfs. Search the threads about Birf Cage and look for proper orientation from @cruiserdan .

Good Luck!

Thanks for chiming in BILT4ME. Here are three more shots of the spindle. The raised shoulder between the inner side where the hub rides and the flange has one deep grove and a couple smaller groves. I don’t know what it’s supposed to look like new but I’m a little concerned about it.

Preload seemed to be non existent when I took it apart, the big 54’s seemed to both be loose, there was no effort to free them once the locking tabs where pushed out of the way.

I also found one of the steering arm bolts loose.

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That spindle should be replaced.
 
That spindle should be replaced.

10-4 CDan. I think I will tear the other side down before a build out a parts list. Have the wheel bearings but I need to replace brake lines after inspecting the DS.
 
More evidence that these 80s can take some abuse.
 
Well the PS is going a little better, preload was lose like the DS but at least there is no oil and the wheel bearings were holding a lot of grease. I promised my wife that I’d knock out dinner this evening so I need to get that taken care of. I’ll finish this tear down later this evening.

Time for a step #6, think I will have a Convict Hill Stout

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Yeah, as Dan said, that spindle is junk.

If the other side has been run as loose as the first one, there is a high likelihood it has been grooved as well. It was the sealing surface for the hub seal that killed it, not the surface where the bearings rest. The bearings had obviously been run EXTREMELY loose to cut that surface like that.
 
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