Build: Another green 80 (1 Viewer)

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Joined
Jan 17, 2005
Threads
239
Messages
7,433
Location
Southern Colorado
Back Story:
I owned a '95 80 that I drove from 75K miles to 200K miles, then sold to a buddy whose kid wrecked it and sold it back to me. I rehabbed and resold it. I never fell as much in love with the 80 series as I did with 40s, 60s, 100s, etc. It did not have lockers and of course, was dark green metallic, like every dang 80 series in Colorado. But, if faithfully toted my wife and my camper all over the place and was reliable. I should mention that my brother owned a dark green '94 at the same time.

Now:
So, a neighbor of mine and an old co-worker had a '93 80 since 2000, and literally didn't even know what the locker switch was for. I have been tracking this (green, of course) truck for years, and he finally sold it to me, tired and weary. Redline Land Cruisers checked it out for him and found a laundry list of leaks, worn items, tired items, etc. It starts, runs, drives, but the front end feels loose and the knuckles leak grease worse than Julian Assange leaks classified information. Very little rust - some in driver's door and surface rust on the hatch. Underside looks great.

So, here is the next green (what other color?) 80 in my garage. Umm - the mileage is correct. I have records from 2000 and it has never had a timing chain or head gasket or any internal engine work. Trans is original and leak free, and shifts properly.

The valve cover was leaking possibly worse than the steering knuckles, so I pulled it and did a compression test, inspected the timing chain, etc. and checked valve lash. Compression is pretty even and well within spec. Valve lash is off for several exhaust valves (.006", .007", versus the .010" minimum). I ran a bore-scope down all cylinders and they show original cross-hatching. The PO was not a wrencher, and just took it to local shops for oil changes and repairs, but it survived in spite of this.

I plan to rebuild the knuckles, drive it some, evaluate, and then decide to keep/sell/horse trade. I love my FJ40 (had it since 1990) and my very clean FJ62 (as honest a rig as Toyota ever made), but an 80 with lockers has chronic appeal. I also have a '99 LX 470 with a swapped in locker axle, so it's not like I'm short on Land Cruisers.

Enough blabber - on with the photos. First shot is my '95, then the new '93:

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Borescope photo - all the cylinders look like this. Then a camshaft shot. Engine is super clean inside.

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Wow looks dam clean for those miles
 
Green is the best color 😂
 
A knuckle and brake job. I had never replaced knuckle bearings in 34 years of fixing Land Cruisers (none every really needed it). These knuckle bearings weren't horrible, but clearly needed replacing - loose in the middle and tight at the steering extremes. No play, however. Big ol' greasy mess, with a heaping helping of Birfield Soup on the side.

Fortunately, the wheel bearings and spindle were in great shape. The Birfields/axles had been replaced with aftermarket by the PO, and they have a small amount of play, but otherwise seem fine. The Cruiser Outfitters kit contents was great, but the instructions aren't great. I watched OTRAM's YouTube video a few times to figure out reassembly. So nice to have a single kit with every gasket and seal, rather than piecing it together at the dealer.

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Installed a Toyota reman (only kind sold at the dealer) alternator - the old one (possibly original) was clattering horribly (rear bearing) and had poor output. Just under $200 at the dealer.

I sure love replacing Toyota alternators - they are always far more of a time-suck than you think they will be. But, the engine is now nearly silent when running, which is a treat.

Edit: guess I'd better tighten the top pivot bolt, shown to be, ummm.... not fully engaged in the photo.

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Another day, another knuckle. Now redoing the driver's side. This one was reassembled with FIP (instead of a paper gasket) and the knucklehead who rebuilt it used a chisel (rather than a 54mm socket) to tighten the wheel bearing nuts. I ground off the curls of steel and the nuts are fine. Gotta love 'Birfield Soup' in the giant size.

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Axle oil change and installed a rust-free hitch and 2 clean running boards that I had stashed.

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Speedo cable adapter lost a few wires when I touched it (they literally fell out), while replacing the o-ring on the speedo housing. Oops. Will fix.

I have another connector to use here. A 100 series alternator cable connector is the same, save for a small rib that can be shaved off.

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Time for a new windshield. Will need to caulk around perimeter, since the glass guy didn't and it has minor leaks. Zero rust around the entire frame area - very cool to find that.

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Will need to caulk around perimeter, since the glass guy didn't and it has minor leaks

This doesn't seem needed but I'll add, as encouragement, that I had to do this when my windshield was installed a few years ago. The installer was light/missed a few sections with the 3M window sealant between the seal and the windshield outer frame/body. These areas were subtle but visible by looking at the profile of the seal and could be found by feeling around with a plastic trim tool.

I ordered the appropriate 3M windshield sealant, extra small-end tips, warmed the sealant up and was able to pretty easily get the tip between the seal/body and fill the voids. The extra tips came in handy as they would get bent/damaged as I ran the bead. I did this within a day or two of the windshield install so that it was still clean and the og sealant was still fresh and it's not leaked a drop in the years since. Anyway, this is not the typical approach and I've not seen it mentioned but was it preferable to a reinstall in my case due to drive times to the glass shop/etc. and it's worked well to date.
 
Just to wrap up the build thread. I got all the leaks stopped - pretty cool to have a 400K mile truck that is dry on the bottom. The windshield leak was 99% solved, if not 100%. I sold the truck to a buddy who bought my '95 years ago, and missed a trail-worn truck. He was very happy to buy it, and I was happy for a parking space back. He hasn't called me yet, so I assume it hasn't tossed a rod through the pan.... ;)
 

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