Build Clifford is home again- a 1965 FJ40 FST

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locklaw said:
Don't forget the pilot bearing in case you forgot about it. Just had one seize up from standing only 9 months. Made no noise before it was driven to its parking spot for the refresh
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For sure! It comes in the clutch kit I ordered from Cruiser Outfitters. I was just asking my wife if we had any sacrificial bread. :rofl:
 
Does anyone have a good source for the felt washer on the vacuum actuator rod? I ended up having to open up the case to clean out old hardened grease which prevented the ball bearing from actuating the 4wd switch. I think I found a good o-ring on McMaster but now I need the felt washer. I may just custom make one, but if someone has an easy source that would be great. :)
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Andrew S said:
Chase, McMaster-Carr has felt washers as well, if you hadn't seen them yet?
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Thanks, I looked but I could only find fat washers. I may get one of those a cut it to the correct OD and ID with a punch.
 
red66toy said:
Does anyone have a good source for the felt washer on the vacuum actuator rod? I ended up having to open up the case to clean out old hardened grease which prevented the ball bearing from actuating the 4wd switch. I think I found a good o-ring on McMaster but now I need the felt washer. I may just custom make one, but if someone has an easy source that would be great. :)
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We have them but only as part of our TCGK6980 gasket kit. Kind hard to tell from the pic but that is this:

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cruiseroutfit said:
We have them but only as part of our TCGK6980 gasket kit. Kind hard to tell from the pic but that is this:

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That felt is actually bigger that the one I need. The one in the rebuild kit fits the lower actuating rod. The kits don’t come with the seals for the vacuum diaphragm rod. It makes sense since the vacuum is not common to all transfer cases, but that lower actuating rod is . The vacuum actuating rod is smaller diameter (about 1/2” diameter).
I did order another internal rubber seal from you all for it though! 3 seals for this system!
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red66toy said:
That felt is actually bigger that the one I need. The one in the rebuild kit fits the lower actuating rod. The kits don’t come with the seals for the vacuum diaphragm rod. It makes sense since the vacuum is not common to all transfer cases, but that lower actuating rod is . The vacuum actuating rod is smaller diameter (about 1/2” diameter).
I did order another internal rubber seal from you all for it though! 3 seals for this system!
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Ah copy, I didn't read back far enough and see you were working on the early vacuum diaphram. I went down the path of trying to build a vacuum diaphram R&R kit like our split t-case version but ran into some discontinued and hard to source goodies. I'll look at my notes and see if I found anything on those. Did you check the old parts catalogs or microfiche to see if they list a part number for that loose felt washer?
 
cruiseroutfit said:
Ah copy, I didn't read back far enough and see you were working on the early vacuum diaphram. I went down the path of trying to build a vacuum diaphram R&R kit like our split t-case version but ran into some discontinued and hard to source goodies. I'll look at my notes and see if I found anything on those. Did you check the old parts catalogs or microfiche to see if they list a part number for that loose felt washer?
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Thanks! The felt seal is 90303-13018
 
The three seals on the system are 90301-12027 (S) , 90303-13018 (T) and 90310-13001 (L). I got seal L from you @cruiseroutfit along with some other parts to finish this project. :D
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Bellhousing on! I needed to put this back on so I could free up the oil pan for removal so I can do the rear main seal.
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I have also been working on extracting some broken bolts while keeping the cages intact. I am going to have to weld on at least one new caged nut.
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Some goodies arrived from @cruiseroutfit :)
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Bread for the win!

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Torqued the bellhousing bolts to 47ftlbs. Now onto the oil pan!
 
Nice work. Did you pre-fit your new pilot bearing to the shaft? There is some discussion about perhaps using emory cloth to make installation go smoothly.
 
Wonderbread 😉
 
Green Bean said:
Nice work. Did you pre-fit your new pilot bearing to the shaft? There is some discussion about perhaps using emory cloth to make installation go smoothly.
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Not yet. But thanks for the reminder! I had forgotten about that little detail. :) I am currently working on tracking down a 4speed flywheel, so it will still be a bit until this assembly gets installed.
 
Roastchestnuts said:
is it weird that I am excited to try the bread trick?
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Oh I was totally excited. :lol: It felt really goofy to be stuffing bread into the engine, but it worked awesome! A brass dowel I had on hand was the perfect size.
 
rfitzpatrick said:
Dude, you make quick work of things! I'm excited about the progress as I'll be doing a lot of these things in the coming weeks ahead. I'm about to drop my transmission and transfer case this weekend and then it's on!
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Thank you! I REALLY want to drive this thing. :D I also dont like any of the rigs to be down for too long, so I am trying to push as much as life allows. Best of luck with your project, you got this. I was pretty nervous about the transmission and transfer case rebuilds, but it was more straightforward than I thought. Especially thanks to all the info here on mud. :cheers:
 
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