Dan's 1979 BJ40

[SurfPonto]

I like the diesel Subarus.
Apparently they are suppose to bring the Boxer Diesel to the U.S. in a year or two.
I will believe it when i see it.

Bob

Righto, so i haven't really done anything to the BJ over the last few months, except drive it. I've cleaned the PTO winch up, greased all the uni's and got it ready to mount, but it's still sitting on my garage floor waiting.

I started a new job early this year and the cruiser was my only vehicle. That meant it got called into action to take me 200km's a day round-trip to and from work. She did it reliably, but damn it is not a highway cruiser! My spine was not happy with me! She also leaks in numerous areas during heavy rain, so that was not cool either with all the rain we have had here in Queensland this month. So i drove her for two weeks and put a good few miles on her, but i think it might have been slowly killing it. I noticed a few days ago my brakes felt abnormal and i saw fluid leaking on the inner side of the rear passenger wheel. I suspect a leaking wheel cylinder. Good time to put the cruiser on axle stands, fix the brakes and finally fit the lockright into the rear diff centre.

While all this was happening i was organising a new lease vehicle through work, to take make my long commute to work faster and safer.

Of course it had to be diesel....
View attachment 486796
A Subaru Forester with the new Boxer Diesel. What can i say, this engine is fantastic. It's mated to a 6-speed manual and they claim you can get 6.4L per 100Km's on the highway, or around 1000km's to a tank. Peak torque of 350nm between 1800-2400rpm is a good place to play around in. It's got a Diesel Particulate Filter (DPF) straight after the turbo, which is the only thing i wasn't keen on. Hopefully i won't have any hassles with it clogging up anyway, due to amount of highway driving i do. Because it's a horizontally-opposed engine it has basically no vibration and sits down really low in the engine bay.
View attachment 486798
View attachment 486797
I'm going to have it for a few years now, so we will see how reliable this hi-tech diesel turns out to be. So far i'm loving it.

 

[Falco80]

Well, i'm an idiot. I always assumed the PTO i picked up would bolt straight up to my transfer case, and well, you know what they say about assumption.

I dropped the oil today and cleaned everything up ready to fit it, but when i removed the cover plate and gasket i found out it wouldn't fit. Damn, i was pi$$ed off. The top and bottom holes align, but the other four are way out. The gear is there on the input shaft ready for it and all.

The HJ47 i got the PTO off was an early 80's model, and my BJ40 is a 1979 model. So am i right to say that 40's from the early 1980's have a slightly different transfer case?
What to do now....?

 

[herbs]

Well, i'm an idiot. I always assumed the PTO i picked up would bolt straight up to my transfer case, and well, you know what they say about assumption.

I dropped the oil today and cleaned everything up ready to fit it, but when i removed the cover plate and gasket i found out it wouldn't fit. Damn, i was pi$$ed off. The top and bottom holes align, but the other four are way out. The gear is there on the input shaft ready for it and all.

The HJ47 i got the PTO off was an early 80's model, and my BJ40 is a 1979 model. So am i right to say that 40's from the early 1980's have a slightly different transfer case?
What to do now....?

Post August 1980 uses the split transfer case, earlier has the one piece transfer.

 

[Falco80]

Thankyou Herbs, i probably should have known that already! It just goes to show how much attention i was paying to the HJ47 transfer case when i was lying on the dirt removing the PTO gearbox from it!

 

[lostmarbles]

Hey Dan.

You don't need to look far to see that the PTO you've got (for the splitcase) is the rarer of the two.

So I reckon you'll easily find someone on MUD prepared to so a swap at no cost to you (even likely from far away where costly airfreight is involved).



Edit: Oops. Forgot it was Thomas brand and not Toyota brand. Still .... someone is likely to be interested because Thomas is reputable.

 

[herbs]

I have one of those Thomas pto winches on my troopy, they're a good unit so someone out there will want it.

 

[Falco80]

Well, I've managed to pick up the correct PTO gearbox for the 40. This one cost me a tad more than a block of rum and coke, but it is the correct one this time.
This Toyota PTO box has forward and reverse function and provision for front or rear shafts, which is cool and are features the Thomas gearbox doesn't.


It's got the magic TEQ logo on the side.



It needs good clean inside the housing. It looks like it has been sitting out in the open and dry of oil for a while. I don't have all the linkages to engage it either, so it will be a work in progress...

 

[stoo]

Nice find cobber!

 

[lostmarbles]

Well, I've managed to pick up the correct PTO gearbox for the 40. This one cost me a tad more than a block of rum and coke, but it is the correct one this time.
This Toyota PTO box has forward and reverse function and provision for front or rear shafts, which is cool and are features the Thomas gearbox doesn't.

View attachment 508410
It's got the magic TEQ logo on the side.
View attachment 508411
View attachment 508412

It needs good clean inside the housing. It looks like it has been sitting out in the open and dry of oil for a while. I don't have all the linkages to engage it either, so it will be a work in progress...

Well done Dan.

Be careful when you come to bolting it up to the transfer case. I found I had to increase the thickness of my gasket to eliminate a loud "whine".

Rum & coke .... Yuck!

And I dig the home-made flange and sawn-off shaft.



PS. Even if you can't find the OEM pivot, lever and rod to operate it .... it would be easy enough to make that stuff up yourself (and have it looking pretty neat too).

 

[Falco80]

Cheers for the tip Tom, I bolted it to the transfer case yesterday and it's functioning good. I used 0.8 gasket paper and i took it for a decent drive this morning to check for any strange noises and it turned out all ok. Everything operates and turns like it should and there's no leaks, so now i can turn my attention to mounting the Thomas winch up front and modifying the Thomas driveshaft to mount to the Toyota PTO gearbox.

Rebuilding the PTO gearbox was very simple and fulfilling. The Toyota manual i have breaks it down into a disassembly/assembly order, so you can't go wrong.

New bearings, oil seals, home-made gaskets and a good clean of all the gears should see this last another 30 years!

 

[Falco80]

Gotta have tunes! I finally got so sick of not being able to play CD's on the old stereo because they would skip all the time, due to the bumpiness of the 40, that I bought a USB head unit (what a great invention!). Now i've got heaps of music at my fingertips and no more skipping during songs!
A decent pair of Kicker 6x9's for good measure and i've now got pretty good sound. It will never drown out the noise of the B diesel, but why would i want to do that anyway?!

 

[baas]

That PTO gearbox looks new well done. Reckon the USB tunes is the way to go, just fitted one to my truck as well. Thanks for keeping us updated Dan.

 

[Jonny Tsunami]

Awesome truck, Good Luck!

Dave

 

[Falco80]

Took the shorty for it's first run (first run with me anyway!) up the beach camping a couple of weeks ago. She went great, but you really notice the lack of power as soon as you hit some soft sand! The locker performed well and the footwell vents let plenty of fresh sea-air in as we cruised from Noosa north shore up to Double Island point. The weather was awesome and the beer was nice and cold.





The week after i got home I was going over her cleaning out sand and stuff from the trip and i started to clean up around the top of the engine while i was under the hood. For some reason i started rubbing back a few sections of the injector lines and before you know it i was addicted and could not stop until they were all polished. Spent a bit of time at night after work over the following week rubbing all four lines back by hand until they were shiny. Crazy i know, and not the easiest when they are still bolted in, but i just could not stop once i got started! I think there is something wrong with me!

 

[Falco80]

Ebay has also been good to me over the last few weeks. I picked up a brand new Toyota SST for the OEM 15600-41010 oil filters for a really good price. This should make the routine oil & filter changes a bit more enjoyable.





I also picked up an early Landcruiser bottle jack. I've never seen one of these on ebay before and the fact that the seller lived just 15 minutes up the road meant i just have to have this! It doesn't have the handle, but it works fine and looks like it comes apart easy so it should clean up well.



Does anybody know approx. what year this jack is from? Toyota part number 09110-26010.

 

[tlc_4play]

You got a great truck to start with
I just dont know how you can resist the temptation to strip it down rebuild it completely and fully restore it to its former glory

Great !

 

[Falco80]

You got a great truck to start with
I just dont know how you can resist the temptation to strip it down rebuild it completely and fully restore it to its former glory

Great !

Thanks mate!
Believe me, if i had more space or a shed i would like to strip it down and refurbish it.
I've been slowly collecting a few hard-to-get OEM parts i've found on ebay for when the time comes that i can commit to a rebuild.

We also have a new member joining the family within the next 6 months, so money and time might also be a bit tight for the next year or so....

 

[Falco80]

Finally got in and did the infamous swivel-hub rebuild. The LH side axle seal was leaking slightly. I put in new Marlin inner-axle seals, new bearings and new gaskets/seals. I used OEM nuts, washers, axle studs and cleaned/re-greased the Warn hubs. I separated the birfield and re-greased them while i was in there too. I used the "steel pipe-against concrete" method to seperate the inner axle and the birfield and it worked awesome.

Just like everybody mentions, it's not a hard job, it's just really messy once you get into it!


Time to get dirty. Lots of crud built up on the swivel hubs...

The kit i used came from Locktup4x4 in Perth, and included "Rock-ring" knuckle felt protectors which are heaps thicker than the stock ones.

 

[Michael Hanson]

Nice work, our 40 used to shake things apart until we put the ome suspension in,unbelievable difference in ride. Mike

 

[Falco80]

Not much been happening on the 40 lately. I've been driving it a fair bit to work and on the weekends. It has been constantly reminding my spine that the springs/shocks need attention. I really need to bring the shackle angles away from vertical. I plan to remove a leaf or two from each spring pack and maybe change shocks, to try to get it riding a bit softer.
Anyway this weekend i finally cut off the lower mounts that the old roof-cage rear legs mounted too, and bolted up some mud-flaps. I think it turned out ok. Sanding-back and repainting the whole rear bar and the bumperettes is on my to-do list.

I also noticed my radiator overflow cap is really deteriorating, so might look into replacing it with something similar, if Mr Toyota can't help me out!