Bj40 clutch ?s

[Jkarow08]

Hey everyone,

I recently purchased the "bastard child" of Central America down here in Nicaragua, a 1972 FJ40 with a 3b swap (Looks like it is from early '85, guessing from a 70) mated to a 4 speed (not sure what year). This week my clutch engagement point started to feel like it was moving and by the time I made it down my rugged jungle trail back home it seemed like I was down on power, assuming it was starting to slip. Upon crawling underneath it I noticed the slave cylinder was attached to the bellhousing with a custom bracket made of two pieces of angle iron. The one piece of angle iron was bent and started to crack on one side, and the resulting twist changed my engagement point. After some digging on here, it looks like I have the incorrect slave for my bellhousing type, guessing the person who did the swap used the slave from the 72 FJ chassis instead of the different version that is used on the diesels. That looks to be an easy fix, simply need to replace the current slave with the correct one. My conundrum though is it appears my clutch fork is the incorrect version for the diesel slave. My fork is too long to align with the bellhousing placement of the correct slave, and my fork has the hole in the end the slave rod protruded through instead of the type with the depression and no hole that the diesel slave utilizes.

So my first question is this...are the two clutch fork types interchangeable? It looks like I'm going to have to drop the trans to replace the clutch anyway so swapping the fork is no big deal, just want to verify it is as simple as swapping one for the other.

My second question is can anyone provide me with a suggestion/part # on which clutch kit to use? If my motor was from an '83 I'd just assume the motor and trans were a matching set and buy the appropriate kit, but considering my motor is from 85 after they had switched to the 5 speed, I'm not sure if my trans is from a gas or diesel and how that effects which clutch I should use. Is there any way to identify from an external view of the trans what clutch is appropriate? I'm a little "lost in the sauce"...

Finally, does anyone know of a source for a new 3b flywheel? It sounds like the 3b flywheel is stepped and I am not sure if there are any machine shops locally that could resurface it, considering just buying a new one if possible. Has anyone had success with a DIY resurface?

I've included some pics so you can see what I'm up against, thanks in advance for your help!

 

[B y r o n]

Maybe you can find the information you need here.

 

[Jkarow08]

Maybe you can find the information you need here.

Thanks! I didn't realize SOR had all of the parts schematics. The problem I still have is I'm not sure exactly what year/model my trans is from and how the combo of trans and engine impacts which individual clutch components I should use and compatability between them. And the SOR diesel clutch kits add another layer of intrigue...it looks like 2/85 is the cutoff date between diesel clutch models...the serial number to year data isn't that well know for the diesels from what I have found but it looks like my engine serial #s date it to early 85 (705940). Now it is even more complicated...

 

[Jkarow08]

Based on the bellhousing style, this is the type of fork and slave I should have correct?

 

[Jkarow08]

That style is diesel specific so that makes sense...

AISIN Clutch Release / Slave BJ40, BJ60 1981-1984

fj40 clutch slave

cruisercorps.com

 

[peesalot]

Yes, get the diesel slave if you can. the fork was used probably because the throw out matched it, IIRC the diesel throw out & fork have a different clip/retainer at the throw out as well as a diff end at slave.

 

[Jkarow08]

Yes, get the diesel slave if you can. the fork was used probably because the throw out matched it, IIRC the diesel throw out & fork have a different clip/retainer at the throw out as well as a diff end at slave.

Perfect, thanks...that's what I assumed based on the bellhousing. Am I correct in assuming the diesel fork is a direct swap with the gas?

That brings me to the clutch...it sounds like the diesel and gas clutches/trans have different spline counts. I have a gas fork and likely TOB...would you/should I assume I have a gas clutch/trans? Is there any way to identify which trans type I have from the exterior?

Thanks for all of the help...this is a new chassis for me and this mystery combo has made my head spin.

 

[peesalot]

Ah, the trans may be why the throw out & fork were maintained, for the fork & throw out I bet you can make it work with diesel slave, it may not have enough travel for the gas pressure plate, I call Georg with these mix match questions, he'll know what works. Georg at Valley Hybrids. Orangefj45 on here.

 

[Jkarow08]

Ah, the trans may be why the throw out & fork were maintained, for the fork & throw out I bet you can make it work with diesel slave, it may not have enough travel for the gas pressure plate, I call Georg with these mix match questions, he'll know what works. Georg at Valley Hybrids. Orangefj45 on here.

Thanks! I just sent him a message...hopefully he can shed some light on my situation.

 

[Jkarow08]

So I had so much difficulty in determining the correct combination of parts, I decided to just reengineer the bracket to make the current combination of parts work again to see if the clutch was still good. After a couple of test drives, it appears the clutch is fine and the combo is again working flawlessly. I just need to find a spring and fab a bracket to connect it to the fork. I'll eventually pull everything apart and put the correct combo of parts in, but this is currently my daily so I'm content with it being back on the road for right now. Thanks for all of the help everyone!