Brakes and engine swap in 3 weeks (1 Viewer)

[Source3]

Can I do it?

Here is the deal....I would like to help out a photo shoot for Fossil (see this post). Since I will be in the area of the photo shoot the week of Dec 18th it would be great if I can drive the FJ40 down to Marfa, TX. I just need to get my brake and engine swap done. I have all the parts for the disk brake conversion. I will start tearing into my axle this weekend. I will let the group know when I get into trouble and need help. Once that is done I can drive the FJ40 to Dan's shop to work on the engine swap.

For the just in case factor that I do not get the work done, is anyone up for trailering the FJ40 down to Marfa? Yes, Fossil will pay for all expenses plus some. If not, I will call a transport outfit. I need to get Fossil a cost by the end of next week.

ADDED THIS:
Ok, I have decided to host an impromptu wrenching day on Saturday (11/21/09). If anyone reads this and has nothing planned and want to help please call me at 350-5535 (obviously a local call in in the ABQ metro area) for direction, times, etc. Dan S. is going to try to make it over on Sunday for the front axle reassembly. Probably could use some help on Sunday too!

Plan for Saturday:

1. Remove rear drum brakes and install Poser's brackets and rotor for rear disks.
2. Tear apart front axle
3. Replace tie rod ends
4. Dry fit proportioning valve

Plan for Sunday:

1. Rebuild front axle for disk brakes using stuff from a '77 FJ40
2. Install rear disk brake calipers

I have not purchased any brake lines. I am hoping I can get everything except the lines done this weekend. The next week I will run the lines. Keeping the hard lines in place. I will need to cut and flare in a few places and replace all the soft lines.

 

[pappy]

The brakes will be a day job.

Don't know about the engine. What are you swapping?

 

[Source3]

A day swap! Not for a rookie like me!

Engine: F to a 2F. 3spd tranny to 4 spd tranny. Keeping my transfer case. Everything is at Dan's shop. He thinks it should be a weekend swap. I give it four days.

 

[Cruisergreg]

A day swap! Not for a rookie like me!

Engine: F to a 2F. 3spd tranny to 4 spd tranny. Keeping my transfer case. Everything is at Dan's shop. He thinks it should be a weekend swap. I give it four days.

If you are swapping all your F induction/exhaust then it is a very easy swap. If you are dealing with a 2F induction system then I would expect some wrinkles.

 

[Bad Mojo]

Hey over Thanksgiving break my dad and I may have some time to give you a hand if you need any help. Just let us know if you need any help and what the times you are wrenching and we will see if it matches with our schedules.

 

[Source3]

Paul:

Is it Dan S. you owe the inner axle too that came with the brifs I got from you? If so, I will give them to him on Sunday.

 

[Bad Mojo]

Paul:

Is it Dan S. you owe the inner axle too that came with the brifs I got from you? If so, I will give them to him on Sunday.

Yep, that would be great if you don't mind.

 

[alia176]

Sorry Andrew, I've been out of the loop on your engine deal. I'll help out Dan in anyway I can but this damn job is just getting in the way it seems!

 

[evanz80]

...but this damn job is just getting in the way it seems!

Join the club!

 

[pappy]

... but this damn job is just getting in the way it seems!

Welcome to the real world.

 

[DanS HJ-45]

Had a real scare there that I would be forced to head to work today.

But then for some inexplicable reason the company called me and cancelled what they were trying to do anyway. I will be there tomorrow morning.

• Do you have a complete set of trunion and wheel bearings?
• Should I bring extra grease, just in case?
• How about a spare knuckle rebuilt kit?
• I'll bring all my tools for pulling the knuckles (like C-clip pliers, brass drift, etc...). Any other fancy things I should bring?

Dan

 

[Source3]

Had a real scare there that I would be forced to head to work today.

But then for some inexplicable reason the company called me and cancelled what they were trying to do anyway. I will be there tomorrow morning.

• Do you have a complete set of trunion and wheel bearings?
• Should I bring extra grease, just in case?
• How about a spare knuckle rebuilt kit?
• I'll bring all my tools for pulling the knuckles (like C-clip pliers, brass drift, etc...). Any other fancy things I should bring?

Dan

Yes to all of the above. And a torque wrench (1/2" drive). And bring a tap or whatever it is called that removes broken bolts. I noticed a broken off bolt on the knuckle housing. The bolt is one of the many that holds the wiper assembly to the knuckle. If we can't get it out perhaps we can use my old knuckle?

I removed the knuckle on out stuff from the both sides today; so we are ready to go. Except I ran out of time trying to remove the bottom knuckle bearing. I will get this tomorrow morning.

Thanks Dan and I am glad work canceled on you!

Furthermore:
Still have a good to do list in addition to the front axle/disk brake swap: mount Poser's brackets on rear, tie rod end swap, mount proportioning valve. Did not get to far today, but learning!

 

[Source3]

Sorry Andrew, I've been out of the loop on your engine deal. I'll help out Dan in anyway I can but this damn job is just getting in the way it seems!

Do not worry. You will have a chance to wrench when you break something going over those speed bumps on the reservations. Also watch out for humps on dirt roads. Some ranchers like to dig a trench across the road and put the dirt beside it. It really slows people down. I saw this in Mexico as well. I want to do it on my street too!