AA Ron's FJ40 refresh (1 Viewer)

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Been a little while and a lot has gone on...with everyone else's projects just not really my FJ40. I suppose that can be a good thing because it means it's still running and going strong, no news is good news right?
Meanwhile, some of my favorite YouTubers ( @BenjaminCA, @40FOX, @Vexvader )have moved on and bought other projects themselves, or are making great progress. Seriously, if you haven't seen their channels, check them out. I know I'm always looking for some good landcruiser content, entertaining and educational.

So I ended up also getting myself a new project as well. Price was right and I've always liked the 80 series too. So if you'd like to check that out it's in my signature line.

In the meantime, I started getting my winch ready to install. I always knew there was something wrong with the winch in that it had some rusted out wires and bolts (possibly overheated). The local (newly reinstated TLCA club Battle Born Cruisers of Northern Nevada) is doing a run in a couple weeks so I wanted to be ready for that. So I go to remove the old wires, make new ones and remove rusted nuts and bolts in the process. There was only one problem, I snapped the rusted bolt off, no problem I can just remove the nut from the stud, clean it up and put a new one on, right? Wrong. Turns out the stud is soldered to this little control system that I think engages the winch when it gets signal from the remote.
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I took it apart to see about replacing it. Well it's ripped off the wire that was soldered to it.
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So I'm thinking my fix could be just to put a new bolt through with the wire wrapped around it and maybe some solder. I don't know how well the solder would stick to the head of a regular bolt as was the case with the original Warn stuff.

If anyone has more winch repair/rebuild experience please school me on if my idea will not work.
 
Yes...he custom made the winch cables. I provided the length and he did the rest. I was also buying the battery cables and wanted them to match. Photo is after cables were installed before the front end was put back together
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Been a little while and a lot has gone on...with everyone else's projects just not really my FJ40. I suppose that can be a good thing because it means it's still running and going strong, no news is good news right?
Meanwhile, some of my favorite YouTubers ( @BenjaminCA, @40FOX, @Vexvader )have moved on and bought other projects themselves, or are making great progress. Seriously, if you haven't seen their channels, check them out. I know I'm always looking for some good landcruiser content, entertaining and educational.

So I ended up also getting myself a new project as well. Price was right and I've always liked the 80 series too. So if you'd like to check that out it's in my signature line.

In the meantime, I started getting my winch ready to install. I always knew there was something wrong with the winch in that it had some rusted out wires and bolts (possibly overheated). The local (newly reinstated TLCA club Battle Born Cruisers of Northern Nevada) is doing a run in a couple weeks so I wanted to be ready for that. So I go to remove the old wires, make new ones and remove rusted nuts and bolts in the process. There was only one problem, I snapped the rusted bolt off, no problem I can just remove the nut from the stud, clean it up and put a new one on, right? Wrong. Turns out the stud is soldered to this little control system that I think engages the winch when it gets signal from the remote.
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I took it apart to see about replacing it. Well it's ripped off the wire that was soldered to it.
View attachment 2581744View attachment 2581745

So I'm thinking my fix could be just to put a new bolt through with the wire wrapped around it and maybe some solder. I don't know how well the solder would stick to the head of a regular bolt as was the case with the original Warn stuff.

If anyone has more winch repair/rebuild experience please school me on if my idea will not work.
Can you take picture of exactly what part was welded to your stud from the motor? Also, your cables look pretty mangled with some bad insulation damage. It almost looks like it has shorted at some point.

Your winch is a Warn? I'm 100% sure Warn sells a replacement stud for that motor. You'll need to call up their customer service.
 
Can you take picture of exactly what part was welded to your stud from the motor? Also, your cables look pretty mangled with some bad insulation damage. It almost looks like it has shorted at some point.

Your winch is a Warn? I'm 100% sure Warn sells a replacement stud for that motor. You'll need to call up their customer service.
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I'm pretty positive the back of the bolt was welded/soldered to these wires, and the reason the insulation is all mangled is from when I tried to zip the nut off using impact drill not knowing there was this underneath. Please if you know of a replacement part I can find then by all means point me in that direction.
 
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I'm pretty positive the back of the bolt was welded/soldered to these wires, and the reason the insulation is all mangled is from when I tried to zip the nut off using impact drill not knowing there was this underneath. Please if you know of a replacement part I can find then by all means point me in that direction.
What model of winch is it?
You can look up the parts diagram at this link.
From there shop for the part online.

Looking at a few of the diagrams though they may just give you a part number for the motor.

I'm pretty sure it's repairable though if you dig around on repairing old DC motors.
 
meh scratch that. I just called they're customer service and they said they don't sell replacement parts for the motor, and I would need to order a complete motor to replace it. Given that information, I think I'll attempt my own repair and see if it works.
 
meh scratch that. I just called they're customer service and they said they don't sell replacement parts for the motor, and I would need to order a complete motor to replace it. Given that information, I think I'll attempt my own repair and see if it works.
I'm confident you can.

Do you have a serial number or model number for the motor? It looks a lot like the motor on my 8274. I could open mine up to show you how it "should be".
 
I actually found another 12k winch on FB market with an extra motor. I'm thinking about contacting the guy and getting that one because I do now have that other project I could possibly use the other winch on. :hmm::hmm::hmm:
Kill two birds with one stone... ;)
 
I hit a little bump in the road today. I guess technically it didn't happen today, I just happened to find it today.

A couple weeks ago I noticed an issue where while I was driving, the e-brake felt like it was engaging. I didn't have time to stop and inspect it until today I decided I would just go "adjust the e-brake position" and then I'm good right? Wrong!

Here's what I found in this order.

1. Pinched/broken brake cable, shucks I'll need to get a new one so let me go ahead and disassemble it to get it loose. No problem still because I can just plug and play a new cable right? Wrong!
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2. After unbolting and removing the drive line, I see the leaking gear oil dripping out. Crap probably a failed seal right? Wrong!
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3. Pulled the black drum off, noticing in my head that it was sort of loose (🤔 not supposed to be that loose right?) As I pull it off, I noticed some dings on both break shoes and wonder what could have caused that they were brand new.
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4. Now it's coming together that things are worse than I expected as I see only 1 of the 4 bolts that should bolt to the speedometer housing hanging in there. Then I see the culprit the housing broke.
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