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- #81
Dave's 1978 FJ40 long restoration project
- Thread starter DSB345
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- #82
Pictures don't do it justice at all
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- #84
OH! I forgot to mention that I received these brand new OEM shackles and pins last week. Guess where I'm going with my suspension?
Looking incredible, that axle is definately 40 porn.................
Dave
I dismantled the transfer case this afternoon. Dave had warned me before he brought the case in that the drain plug was frozen, and that he'd rounded off the plug and gouged the case trying in vain to get it out. Sure enough, Even laying the case on the ground and whacking the drain plug with a chisel wouldn't do it. So I resorted to a trick suggested by Pinhead: I welded a nut right over top of the plug. Worked like a charm.
I will get it hot tanked tomorrow and evaluate whether it's gonna be cheaper to weld up the aluminum you ground off or just replace the case.
Should have a progress pic on the rear end too.
I dismantled the transfer case this afternoon. Dave had warned me before he brought the case in that the drain plug was frozen, and that he'd rounded off the plug and gouged the case trying in vain to get it out. Sure enough, Even laying the case on the ground and whacking the drain plug with a chisel wouldn't do it. So I resorted to a trick suggested by Pinhead: I welded a nut right over top of the plug. Worked like a charm.
I will get it hot tanked tomorrow and evaluate whether it's gonna be cheaper to weld up the aluminum you ground off or just replace the case.
Should have a progress pic on the rear end too.
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- #88
Axleshafts and wheel cylinders are on.
Forgot to show this to you when you were here:
No credit here, except for being a hoarder: it's a NOS cluster.
Got the case back from hot tank. I don't think the gouges you made are structural. I can certainly weld it back up and smooth it down. It's just time. Plus time to clean it up. I have an empty case that will probably end up being more cost-effective.
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- #94
I think the new case is more cost effective, Mark. I'm very glad I'm having you do this right so I don't have to fix my mistakes later and I know I have a sound drive train that will be dependable for many years to come. Your doing a fantastic job for me. Very professional top notch skill and expertise. I'm learning a lot and having fun too 
Dave
Dave
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- #95
What mark is trying to say is when I originally tried to remove the plug to drain the transfer case, I tried the correct socket with a rachet but it wouldn't budge. Then, I resorted to a wrench and hammer and that didn't work. I was thinking, I will just get our my IR gun with 780 ft. pounds and that should work for sure. It stripped all the corners of the nut instantly. So I thought hummm, now what. I have that really nice Makita grinder what if I grind down the nut into two flat spots and use the good ole' vise grips and hammer trick. Surely that would work. As I was grinding down the nutwith ambers flying into my face and on my clothes, I pulled the Makita back to take a look at my progress and saw that I had accidently ground right into the case a little. I dropped the Makita and just laid there awhile looking at my stupid mistake and said to myself, That's going to cost me big. I got out from under the rig and gave up for the day. 
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- #96
Nice!
Man i took my transfer plug out for the first time the other day and it was really stubborn and stripped from PO, what I used was pipe wrench . Those things will bite into whatever u got , just go easy and let it get a good bite and have at it . Worked for meWhat mark is trying to say is when I originally tried to remove the plug to drain the transfer case, I tried the correct socket with a rachet but it wouldn't budge. Then, I resorted to a wrench and hammer and that didn't work. I was thinking, I will just get our my IR gun with 780 ft. pounds and that should work for sure. It stripped all the corners of the nut instantly. So I thought hummm, now what. I have that really nice Makita grinder what if I grind down the nut into two flat spots and use the good ole' vise grips and hammer trick. Surely that would work. As I was grinding down the nutwith ambers flying into my face and on my clothes, I pulled the Makita back to take a look at my progress and saw that I had accidently ground right into the case a little. I dropped the Makita and just laid there awhile looking at my stupid mistake and said to myself, That's going to cost me big. I got out from under the rig and gave up for the day.
Dave
You asked me to keep you posted on the timing cover. Today is engine day at the house. I am working on the 45, stripping the F.5 I just got from South Dakota, and yours is right here too. I've decided to powderpaint my timing cover. It's just addictive, seeing that paint.
Just reassembled my radiator core support.
Bling!
So you want me to get yours done too. The timing cover on that motor already has a fresh seal and gasket on it I will have to redo if I pull it. LMK
You asked me to keep you posted on the timing cover. Today is engine day at the house. I am working on the 45, stripping the F.5 I just got from South Dakota, and yours is right here too. I've decided to powderpaint my timing cover. It's just addictive, seeing that paint.
Just reassembled my radiator core support.
Bling!
So you want me to get yours done too. The timing cover on that motor already has a fresh seal and gasket on it I will have to redo if I pull it. LMK
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- #99
Rear brakes are done:
Started on the steering box today and had a bellhousing hottanked.
Started on the steering box today and had a bellhousing hottanked.