Builds An HJ61 followed me home to Texas

[bottombracket]

Now back to the HJ61 woes:

I called @beno. If the OEM radiator is available and it don't break the bank, I'm going to replace my 30 year old one with a brand new one.

Now I just have to figure out how to get the 4th bolt off of the exhaust manifold and yank the turbo. There is no logical way to do this....do I really have to remove the brake booster, master cylinder, and the entire damn left fender???

 

[ceylonfj40nut]

Things were coming together. However, I thought the left rear wheel cylinder was leaking. When I pulled the drums off, it wasn’t brake fluid…
View attachment 1829292

Luckily, my good friend AJ @aljollano came to the rescue and we pulled the diff cover, pulled the rear axle shafts, and replaced both rear axle seals. And the e-brake cable that was about to totally give out. Thanks also to @tucker74 who loaned me a diff cover gasket until I can get a replacement so I could finally get the truck on the road.

View attachment 1829289 View attachment 1829291 View attachment 1829293

Somewhere along the way, @davegonz helped me put in the FJ80 master cylinder. Amazingly, I don’t have pictures. We finally have bled the brakes and the old truck who is roadworthy once again.

All in all, between all of the learning curves, parts needs, and my weird work schedule, the truck was off the road for about five months. I’m pretty sure this is the longest birf job ever recorded.

Does it stop better with 80 master cylinder?

 

[bottombracket]

The short answer: yes.

The long answer: I still think I have air in the system and I need to adjust the brake booster pushrod. If I can’t clear the LPSV of air I may just take it out, run new lines, and put a manual proportioning valve in the front. Time will tell. Right now I have the whole front of the motor torn apart so it certainly won’t be driving anywhere for quite a while.

I like that the remnants of the 12HT sticker are still visible.

 

[bottombracket]

I finally got the fourth bolt between the exhaust manifold and turbo flange off with a stubby 14 mm Gearwrench. Thank God for those tools.

I drained the oil and water last night and I’ve only got two bolts and the water pipe holding the turbo in place. There are two manifold bolts left to get and the whole thing should come apart.

I’ll check the axial play in the turbo, but I’m sure that the seals are blown. I’ll most likely be sending it to Majestic Turbo in Waco, just 100 miles up the road from me.

Surgical lap sponges can be stuffed anywhere.

 

[bottombracket]

Thermostat was filthy and corroded. A new water pump and new thermostat will be going on in addition to the new radiator from @beno.

 

[davegonz]

Are you going to swap out those little heater hoses near the thermostat housing? They look original.

 

[bottombracket]

Yes, I have an OEM replacement for it. I may reuse the clamps, but I have a bag of @Racer65 stainless clamps just begging to be put to use.

 

[bottombracket]

The water hose union joint was destroyed. Found new ones.

87251-30200

Thanks to @MCJakeCrim for pointing me in the right direction here.

Now I need the hoses that link up to the water pipes on top of the motor...paging @beno...

The internal diameter of my nasty 30 year old hose and the external diameter of the hose barb measure 16.5-17mm. Time to research metric heater hose standards.

 

[OGBeno]

Got ya covered.

 

[bottombracket]

Found the fittings, but need hoses.

I’ll head to NAPA and see if they have a decent match of 5/8” heater hose to match mine as the originals are NLA.

In good news, Toyota still makes the radiator overflow bottle. I’m in ‘buy every part for a 12HT that Toyota still makes before they quit’ mode.

 

[bottombracket]

FREEEEEEEEDDDOOOOMMMMM!

Tonight I finally got the turbo and manifold off.

There is a small amount of side to side play and a tiny bit of axial play that I think I can discern with my fingers. I don’t have a runout gauge but the turbo is definitely going off to get rebuilt.

I gave the exhaust manifold a quick look and it doesn’t look like it has any cracks. I will need to clean it up and go over it very carefully. If the two sections are still together, should I risk taking them apart as finding the steel rings and O-rings is currently difficult?

The wastegate and flapper are definitely not moving right now. I wonder if they haven’t moved in decades?

I can’t believe that I did all this work for two broken manifold studs. However, I’m doing a lot of preventive maintenance now that I’m in this far and I’m probably extending the life of the motor by paying attention to the cooling system and turbo.

 

[Mr Cimarron]

Where are you sending the turbo for rebuild?

 

[bottombracket]

I’ll call Majestic in Waco and see what their turnaround time is. Any other recommendations?

 

[davegonz]

Talk to John Walzel. He's a Toyota guy and was very friendly and responsive when I sourced my rebuild kit.

John Walzel

Majestic Turbo Waco
815 Jefferson Ave.
Waco, Texas 76701
254-757-3759
www.majesticturbo.com

 

[Mr Cimarron]

Austin Fuel Injection & Performance Center
Great group of diesel guys up there.

 

[OGBeno]

Talk to John Walzel. He's a Toyota guy and was very friendly and responsive when I sourced my rebuild kit.

John Walzel

Majestic Turbo Waco
815 Jefferson Ave.
Waco, Texas 76701
254-757-3759
www.majesticturbo.com

Do they rebuild Toyota turbo's?

 

[bottombracket]

Majestic does have experience with Toyota turbos. I talked to John this morning.

I’ve talked to Austin Fuel Injection and I know that they could do my injectors and maybe the pump if needed, but I think Majestic has more experience on old Toyota turbos.

 

[Mr Cimarron]

You can also rebuild the turbo yourself. My Holset was pretty easy.

 

[bottombracket]

This thing is crusty and I’m a little scared to start with this one. The wastegate is stuck closed and the linkage won’t budge. I honestly don’t know if it has ever been off of the truck. The mounting studs on the block are still bright factory 12 HT blue underneath.

When I go down the 1HZ turbo route for Barney I’ll feel more comfortable doing a turbo rebuild on my own.

 

[Mr Cimarron]

This thing is crusty and I’m a little scared to start with this one. The wastegate is stuck closed and the linkage won’t budge. I honestly don’t know if it has ever been off of the truck. The mounting studs on the block are still bright factory 12 HT blue underneath.

When I go down the 1HZ turbo route for Barney I’ll feel more comfortable doing a turbo rebuild on my own.

Yeah the hard part is getting everything apart.