Builds Clifford is home again- a 1965 FJ40 FST

[Green Bean]

Is it leaking between the engine and the pump or between the pump and the backing plate? Not that it really makes much difference. It is annoying. As I learned, the water pumps require taking the back off and applying RTV on both sides of the gasket and re-tightening the screws. Why they don’t do that at the water pump factory, who knows.

 

[red66toy]

Is it leaking between the engine and the pump or between the pump and the backing plate? Not that it really makes much difference. It is annoying. As I learned, the water pumps require taking the back off and applying RTV on both sides of the gasket and re-tightening the screws. Why they don’t do that at the water pump factory, who knows.

It looks to be the gasket between the pump and backing plate. I’m going to drain the system tonight and check for flatness. Hopefully for the last time with this pump.

 

[red66toy]

Let’s party

 

[rfitzpatrick]

Is it leaking between the engine and the pump or between the pump and the backing plate? Not that it really makes much difference. It is annoying. As I learned, the water pumps require taking the back off and applying RTV on both sides of the gasket and re-tightening the screws. Why they don’t do that at the water pump factory, who knows.

Well crap - I wish I had known this a few months ago. Guess I'll have to keep my eye on it once I get it running.

 

[mrboatman]

That would have been considered a self healer in progress

 

[red66toy]

Pump is back in!
As luck would have it, we had a thick stone counter top remnant in the basement that was very flat. So I took both the pump housing and backing plate and sanded it on the backside of the counter (my wife doesn’t need to know I used it). The outer edges of the housing around the bolts were not flat. They would contact the backing plate before the rest of the plate. This would prevent even compression of the gaskets.
Happy to say that after the sanding I had a nice flat fit between the housing and the plate. I used the Fel-Pro 3075 gasket material but this time I only used a thin layer of Permatex Hi-tack gasket sealer. I think the RTV last time was not needed and maybe didn’t help in even compression.
Fingers crossed the pressure test later today goes well.

 

[red66toy]

I wish I could say that was the end of the saga. I wish I could say I was still sane. But both would be a lie.
Well after I let the high-tack sit for a while, Pressure tested... leaked worse than before! So High-tack is not the way maybe. Making it perfectly flat maybe didnt make a difference.
I yelled a few choice words into the void that is the dark heart of the water pump and took it back off. At this point I was pretty fed up. I had once ace in the hole, or so I thought. I had a NOS pump on hand to try. Brand new, had to be perfect right?

It had a OEM paper gasket on it still that looked in great condition. So I tightened the flat head screws down and bolted the pump up with high hopes.
Failed... worse yet. The OEM paper gasket soaked up the coolant and leaked it out like a complete drunkard! Arg.
Off it came again!
This time I ordered new allen head flat head screws so I could tighten them down much more than the strip-easy OEM Phillips head screws. My thinking was maybe the issue before was I couldn't get the OEM screws tight enough to seal nicely. I cut yet another gasket and used grey Permatex water pump specific RTV. I put on a nice bead (not too much). Lightly torqued, let it cure an hour and then full torqued. Let it cure for 24hours and then came the test. 10psi here we go!
Weeping coolant! Not bad, not like before, but weeping coolant between the pump and backing plate in the same exact spots......

So at this point I am toasted on this. The next try was use a rubberized cork gasket, maybe it would have a bit more squish than this Fel-Pro gasket I have put way too much trust in. I was tempted to just leave it be for a bit and see if it stops itself (fantasy maybe). But that black water pump would be like the tell-tale heart. I would know it’s under the hood, waiting for me. Weeping louder and louder.
On my second pump I cut a rubberized cork gasket. A thin layer of the grey RTV:

This time I rigged up a way to pressure test the sealed pump on the bench and it passed!!!! No leaks. I then installed on the truck, no leaks! Thanks the gods!

I am so happy to put this all behind me. I am going to have our local gasket maker cut a few of these gaskets in case any other 1960s 40owners also have this issue.
Thank you to @Kleatus and @OGBeno for advice.

 

[Roastchestnuts]

I would have lost my s*** if that had happened to me when I was putting together the 2f. Glad you finally got it. and its good info on it!

 

[charliemeyer007]

A lot to be said for clean, flat/straight mating surfaces. Choice of sealant and gasket material can make the difference as well as the technique and torque sequence. Good job working it out - Doesn't at least one of the bolts require sealant on the threads.

 

[Green Bean]

Nice persistence. Glad you got it fixed. Now, we're all anxiously awaiting the video of you driving your new 4-on-the-tree.

 

[red66toy]

Nice persistence. Glad you got it fixed. Now, we're all anxiously awaiting the video of you driving your new 4-on-the-tree.

Me too! I’m held up right now by the local gasket makers. I need the templates I gave them back so I can put the fuel system back together. Should be any day now at least.

 

[red66toy]

Just got word gaskets should be done tomorrow. Excited to fire this 40 up!

 

[red66toy]

Fuel system back together!

About time to pull this out of the garage and fire it up. I just want to drive it!

Also, I definitely need to recover these seats later. Talk about barely hanging on.

 

[red66toy]

It’s moving!!! I am finishing some tweaking to get optimal shifting but it’s driving well. I’ll get a better video soon. Here I am testing if 4wd and low range work. So far so good!

 

[red66toy]

Also, driving with no hump is so stinkin loud and hot. Hahaha. I need to finish that and get it on soon. But I do love seeing all the linkages working

 

[Skreddy]

Also, driving with no hump is so stinkin loud and hot. Hahaha. I need to finish that and get it on soon. But I do love seeing all the linkages working

I was running around no top or doors and it was still so hot with that tunnel off it was unbearable.

Glad there’s another 4 on the tree in the wild!

 

[red66toy]

I was running around no top or doors and it was still so hot with that tunnel off it was unbearable.

Glad there’s another 4 on the tree in the wild!

It’s working fully now! I had to mess with the linkage lengths a little more. 4 speeds on the column! So so fun to drive. That synchronized 1st is so nice and the better gear spread.

 

[Green Bean]

That’s is so cool. Maybe you should get a see-through tunnel cover.

 

[red66toy]

That’s is so cool. Maybe you should get a see-through tunnel cover.

That thought crossed my mind. hahaha

 

[red66toy]

I need to fix my speedometer. It’s not reading well at all. Anyone know a good thread for cleaning/refurbishing it?

Went for a drive in the 40 yesterday. Fixed a leaking clutch line. I have a squeal from the belt I think but I need to investigate more. Hoping it’s not the alternator or something. But I am so in love with how fun this old rig is to drive.