- Thread starter
- #61
The drivetrain is all bolted back in. A couple of friends helped me push it outside where we degreased it and pressured washed it.
Fergytoy"s 1978 FJ40 frame off resto.
- Thread starter john657
- Start date
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- #62
Bolted the exhaust back in with a new collector gasket.
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- #63
A buddy and I sanded and wire wheeled all my metal brake and fuel lines. Used a graphite colored paint to make them look like new. I wanted to install the lines that run along the frame rail and under the tub as it is much easier now than after the tub is installed.
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- #64
After installing the brake and fuel lines on the chassis, I began to install the new polyurethane body mounts. Pua came over and helped me lift and install the tub onto the chassis.
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- #65
The tub is all bolted down and secured to the frame! Woohoo..... Progress!!! I am planning on having it pretty much completely done and back on the road hopefully sometime in April.
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Man! That's gotta be such a good feeling! Congrats on reaching this milestone! Keep it up, she's looking beautiful.
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- #67
Thanks. I am not quite maintaining my goal of doing something on it everyday due to work, family and other commitments, however, I am happy with the progress so far though. 
Great job John. Good reason to be proud.
...via IH8MUD app
...via IH8MUD app
- Thread starter
- #69
Well, its been a while since I posted up here. My wife and I took a trip to Maui, Hawaii for about 9 days. Beautiful area. While in Maui, I managed to take some pics of the local homegrown MauiBuilt Toyotas on the island. There were far more Toyota mini trucks on that island than any other make of truck. I could not get a pic of everyone I saw but the vast majority were running lifts and bigger tires. Nothing over 38 inchers were seen. I enjoyed seeing all the older 79-85 trucks that were not rusted out. Just about all of them had no visible rust anywhere on them. I only saw the back end of 1 FJ40 just off the freeway in Honolulu. No other 40's in sight. We did drive all over Maui and circled it twice!
Just before we flew out, I asked my wife to pick up some white and red artists paint pens from the crafts store and she brought me a Fine and Ultra Fine tipped pens. I saw another Mud member post up about using these pens to fill in dash pull knobs on their 40's to make the knobs look like new. I intend to do the same when I get to the dash portion, however, I thought I would try it on the free wheeling hubs before I re-installed them. I found that the Ultra Fine tips work the best as they are small enough to get into the grooves of the words on the face of the hubs.
Just before we flew out, I asked my wife to pick up some white and red artists paint pens from the crafts store and she brought me a Fine and Ultra Fine tipped pens. I saw another Mud member post up about using these pens to fill in dash pull knobs on their 40's to make the knobs look like new. I intend to do the same when I get to the dash portion, however, I thought I would try it on the free wheeling hubs before I re-installed them. I found that the Ultra Fine tips work the best as they are small enough to get into the grooves of the words on the face of the hubs.
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- #70
Here are a few pics of the Maui rigs. Look at how clean the older rigs are. You may notice that 84-88 4wd mini's have the "lipped" beds that were only put on the 84-88 2wd mini's bound for the mainland US.
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- #71
Here is the Jeep we had rented. This pic was on the very far end of the Hana Road for those of you familiar with Maui. That was as far as I wanted to take it off road. They did not have any FJ40's for rent at the rental store! It worked well and was fun to drive.
Saw a lot of Hawaii 1962-66 in the Navy. Stationed on Oahu but visited Kauai and Hawaii and a couple of smaller islands but don't think I saw Maui. Question: did you really need to go all the way to Hawaii to get those paint sticks? ; )
2008 FJ Cruiser expedition ready and overland trailer w RTT.
2008 FJ Cruiser expedition ready and overland trailer w RTT.
- Thread starter
- #73
Found some time to work on the '40 some more. Began to pull some parts from the boxes such as the steering center arm and power steering box. I had disassembled the center arm, regreased it and then reassembled it. Both were painted and then reinstalled. I also installed the remaining 3 tie rod ends onto the relay rod and draglink. The rods were then installed onto the chassis. I also cleaned up the canvass type cushions that go between the frame and the rear cross member of the back part of the tub. All 4 metal clips that secure the cushions were cleaned up and repainted. They were reinstalled. I like to use anti-seize on the threads of tie rod ends to allow for easier adjustment when doing an alignment.
I also spent a good bit of yesterday going thru all of my old seals, gaskets and grommets to try to determine what needs replaced. I was focusing on the firewall and tub floor grommets/seals that the electrical, heating and fuel lines pass thru. I intended on replacing most if not all of them but after several hours of research, I was able to determine that not all of them are still available. I was able to order about half of them from CruiserCorps and some more from Cool Cruisers. I then made an in-store visit to my local Toyota dealer to inquire about the rest. I was surprised to find out that several more were available from Toyota. The more generic type of grommets and plugs will have to be sourced elsewhere.
I also spent a good bit of yesterday going thru all of my old seals, gaskets and grommets to try to determine what needs replaced. I was focusing on the firewall and tub floor grommets/seals that the electrical, heating and fuel lines pass thru. I intended on replacing most if not all of them but after several hours of research, I was able to determine that not all of them are still available. I was able to order about half of them from CruiserCorps and some more from Cool Cruisers. I then made an in-store visit to my local Toyota dealer to inquire about the rest. I was surprised to find out that several more were available from Toyota. The more generic type of grommets and plugs will have to be sourced elsewhere.
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It was great seeing your 40 in person. I can't imagine how rewarding it will be for you to drive it again.
My wife and I got married on the beach in Hana, thanks for sharing those pics. I'd love to go back there sometime. I noticed the "island style" toyotas as well, maybe you should put that balloon style rim/tire combo on your cruiser?? Jk!
Those hubs turned out great!
-Kyle
...via IH8MUD app
My wife and I got married on the beach in Hana, thanks for sharing those pics. I'd love to go back there sometime. I noticed the "island style" toyotas as well, maybe you should put that balloon style rim/tire combo on your cruiser?? Jk!
Those hubs turned out great!
-Kyle
...via IH8MUD app
John, have you tried Cruiser Outfitters in Sandy, Utah? Kurt Williams has a rep for sourcing hard to find parts.
2008 FJ Cruiser expedition ready and overland trailer w RTT.
2008 FJ Cruiser expedition ready and overland trailer w RTT.
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- #76
I've checked his website and it did not list that grommet. I may call him tomorrow and inquire.
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- #77
Ace, I called and talked to Kurt. He doesn't have it and does not list it. The grommet is obsolete from Toyota and I have no other leads at this point but to do what another Mud user had done which is to modify the heater line grommet which is a double- holer to make it fit. I just may do that...............
Is this unique? You can't just get a generic one at a parts store?
2008 FJ Cruiser expedition ready and overland trailer w RTT.
2008 FJ Cruiser expedition ready and overland trailer w RTT.
- Thread starter
- #79
No, this double hole grommet is very unique. Was back in at the Toyota dealer a few days ago and asked the Parts person about any other Toyota vehicles that may have the same double hole grommet and was told Toyota only did that for the FJ40's and maybe a few others around that time. None of the newer vehicles have this type anymore.
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- #80
Well, I have reached the point of beginning to pull parts/assemblies out of the boxes to recondition them. I have a plan of disassembling several things a day and determining if anything on the assembly needs sandblasting to get rid of rust or if I can wire wheel it and paint it. I am also taking notes on any seals, gaskets, grommets, etc. that may be needed to be acquired to thoroughly recondition it to like new condition. Most of the seals/gaskets/grommets I have been able to source thru CCOT, CruiserCorps and my local Toyota dealer. Some, like the previously indicated double hole grommet for the fuel lines on the floor of the tub between the front seats is obsolete thru Toyota and any other aftermarket source. It has been very time consuming to source many of these parts.
Brake booster prior to reconditioning.
After reconditioning. Big shout-out to Hugh at Safari Ltd. for sourcing the discontinued boot for the booster!!!
Cherie, my parts specialist at my local Toyota dealer printed out a copy of all the grommets, seals, clamps, etc. that are part of the parts assemblies for my FJ40 when it was originally built. This spec sheet also has the sizes of the grommets noted in mm's. I have used these spec sheets to try to determine which grommet is the correct size after measuring the drain holes in my tub that were missing the original plugs or were in such bad shape due to age.
This grommet is obsolete from Toyota but after taking some measurements, I was able to source it at True Value. The wiring harness that runs to the license plate lights on the ambulance door threads thru this grommet.
These grommets are also obsolete but True Value came thru once again. These go around the fuel vent line that runs under the tub and up thru the boxed floor support behind the front passenger seat into the emmisions venting asssembly. Each grommet surrounds the fuel vent line as it enters and exits the boxed floor support.
Brake booster prior to reconditioning.
After reconditioning. Big shout-out to Hugh at Safari Ltd. for sourcing the discontinued boot for the booster!!!
Cherie, my parts specialist at my local Toyota dealer printed out a copy of all the grommets, seals, clamps, etc. that are part of the parts assemblies for my FJ40 when it was originally built. This spec sheet also has the sizes of the grommets noted in mm's. I have used these spec sheets to try to determine which grommet is the correct size after measuring the drain holes in my tub that were missing the original plugs or were in such bad shape due to age.
This grommet is obsolete from Toyota but after taking some measurements, I was able to source it at True Value. The wiring harness that runs to the license plate lights on the ambulance door threads thru this grommet.
These grommets are also obsolete but True Value came thru once again. These go around the fuel vent line that runs under the tub and up thru the boxed floor support behind the front passenger seat into the emmisions venting asssembly. Each grommet surrounds the fuel vent line as it enters and exits the boxed floor support.
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