Build FJ45SWB recovered from a barn

[Michael B]

wow ! there should be a post for all us dreamers who wish they could find a ''BARN FIND'' !
cool find !

I have a thread for that!

 

[west aussie]

Threw some parts at the engine.

just been reading your thread jim. i have an early f motor on the engine stand at the moment. nothing serious; just a quick clean/inspect and slap back together. my book is quiet specific that the rear main seal is to be done with the oil pan in situ. cant see how it makes a bit of difference myself. wondering what your opinion is? just asked the same question in my... ahem...'build thread' over on the 25 page.

 

[FJ40Jim]

Thread dredge!
Worked on the 45 a bit over the past couple weeks. Step 1 was get it parked right in front of a bay door, not parked out in the back 40.
Then removed the 2 radiators, 2 transfer cases, and 2 spare tires from the bed. Then shoveled 20 years of leaves, nut&bolts, desert dirt and raccoon poo outta the bed. There isn't any paint on the bedfloor, but there's no holes either.

The 2 cases in the bed were the original 1962 and a 1969. The 69 turned out to be junk, only coughing up a few small parts. The 62 had very worn shift splines & shift collars. A donor 1980 case coughed up excellent shafts, frt flange and park brake.
The rebuilt hybrid t-case is almost done. Still working on the front drive vac diaphragm assembly. Both were full of rust/mud/water.
Pic below shows case as it sits now, with muddy diaphragms awaiting cleaning.

Second pic shows name on 62 t-case. Anybody know what an AICO case is?

More pics later!

 

[chookenz]

Looks like an original 3 speed transfer!
Very nice find especially in its condition, even the landcruiser on the bezel is a good one

 

[Splangy]

Looks like a 1963+ case. The 1961-1962's were a lil different.

 

[65swb45]

Looks like a 1963+ case. The 1961-1962's were a lil different.

Agreed. Jim, an easy way to also I.D. a early t-case 'on the fly' would be whether the actuator linkage for the front wheel drive was external or internal. The diaphram moves a rod that push/pull the rod the fork is attached to. While that function is performed inside a sealed housing on the later vacuum transfers, it is external on the really old ones. Never looked into production date changes to nail this down, but experience places it at mid-65.

Mark

P.S. I don't believe you on the bed. ALL the swb's fall prey to some rust at the pillars that support the quarter panels. Mine was west-coast clean, but still needed a little love.

 

[FJ40Jim]

The 62 t-case has the exposed 2/4WD linkage (left), vs the '69 enclosed linkage (right).

The exposed linkage was corroded & stuck, but it eventually came apart after some PB blaster soakage. Amazingly, the rubber diaphragm was still in perfect condition after 50 years. The rubber boots for the 2 shafts will be (attempted) ordered tomorrow. This is what it looks like after cleaning, de-rusting & reassembly.

Check out the weird low-speed gear. The gear is riveted to the hub. Note the 2 different part #s for the 2 sections of gear.

The other gear has the early format part number:

The last step for this case is clean & instal P-brake stuff, which is all coming off the '80 case, then it's time to dig up a 4speed tranny.

 

[Splangy]

That's weird, Jim. It looks like a 1961-1962 gear in a 1963+ case. The 1961-1962 cases are easily recognizable from the outside by the smaller 4-bolt input shaft cover:

It's probably a bit of a hybrid like a lot of other things were during the 1962-1963 transition.

Any wobble in the two pieces of the gear? The rivets tend to wear out on those old two piece gears and create some play between the two parts.

 

[FJ40Jim]

Thanks for the pic, Splangy. It does look like they used whatever parts they had on hand to put this together. and now I have further muddied the water by using the 1980 nosecone, output flange, shaft, brake drum, speedo gears...

Speaking of early stuff, does anybody need an early manual priming lever fuel fump? I was running this one on another engine, but it leaks oil and I've already got a rockauto closeout deal on a new pump for the new engine.
This is what it looks like now. 1962 pump lower body, 1978 upper half to get the fittings oriented correctly for oil cooler. I can probably come up with the original upper half. No reasonable offer will be refused! Buy now! Operators are standing by!

 

[pardion]

Need a few small parts for early engine:
Temp sender unit (83420-20010) and the tall socket it sits in (90404-16164).
Oil pressure idiot light switch.

Both parts are different from later (1970s era) stuff.
LMK if you got one.

Jim, I probably have a sender and tall socket. PM if you still need one. John

 

[FJ40Jim]

Thanks John. Still need the early water temp sender & socket (any of those in yer pic will work). Also need a oil pressure switch, since this truck has the oil light in the cluster. PM sent.

 

[FJ40Jim]

Today's progress update:
Cleaned the schmuttz off the p-brake pieces & reassembled. Cleaned & painted drum & rear cone cover. Dug up the 10/74-3/75 H42/J30 adapter gear. Waiting on a 1974 p-brake cable to come from Toyota. I hope it is long enough for 4-speed, but still has an end that plays well with early p-brake handle.

Next step is prep an H42 tranny to mate to this case. Fortunately H42s never need rebuilt, they just get thrown away if broken. Rooted around under the workbench and found one that looked pretty good in & out. The top was removed to inspect, found that the teeth on the 3-4 syncros were worn a little, but not worn out. Since I had the gun in my hand, I also knocked the input snout off just be sure the input seal & front bearing were good. Well, that turned out to be an excellent idea as the input seal was turned inside out. No pics of that, but my spidey sense told me that the oily front of the trans deserved a little more investigation. The seal is already removed and the grimy snout is soaking in the tank. Otherwise, everything looks fine. Washed off the outside of the transmission case for a coat of prime:

Tomorrow that will get paint, and the cleaned snout with a new seal will be bolted back on.

Casting date on the tranny is 9 1 C. I think that means 1979 March.

 

[tornadoalleycruiser]

You can use the old ebrake handle with newer cable just swap parts around.

 

[FJ40Jim]

Thanks Erik!

I thought I tried that on a previous 3spd --> 4spd swap and found the 78 cable (that drops down through the floor) was too short to do the longer 1970 routing out through the top of the firewall... ?

Either way, the truck has a 3spd cable that will be too short, and there wasn't a really good looking used 4-spd cable laying around here. So I had to actually spend money.

 

[FJ40Jim]

Here's today's pitcher post. Yesterday the trans got painted. Last night the tranny snout got cleaned & painted. Whacked in a new frt seal, then bolted it on. Ta-dah:

The winch fairy whispered in my ear that a PTO winch setup will be under my Christmas tree. So one more part is needed before the T&T can be assembled: a PTO drive gear.
Well dangit, there's no 4spd PTO gear loose on the shelf, so another 74 4spd combo needs to be split open *today* to get out the PTO gear. I will get a new one eventually, but the tranny/t-fer/engine needs assembled and slung into the chassis yesterday, to make room for paying work.

 

[FJ40Jim]

Now that the paint is dry, the trans is flipped over to wipe out any remaining schmutz and clean the top rail. There's a little rust haze on 1st gear, but that will polish itself away in the first 10 miles of driving with fresh oil in there.

Big thanks to Alberto for stopping by today to help with this. We excavated a bunch of tranny stuff to dig out a '74 T&T from underneath a workbench and split apart to get a 4speed PTO gear. The transfer input gear is on the left, PTO drive gear on right. Note that PTO gear has machined shoulder that faces front. Also note the 'adapter bearing' which is cataloged as 1970's Nissan 210 rear axle bearing.

Finally, all the critical parts are here to mate the tranny and transfer.
Order of operations:
Stand the transmission up in the special factory assembly jig,
put the gears & 5 big bolts in the t-case,
glue gasket to back of tranny,
carefully slide t-case onto transmission,
snug up bolts,
drive rear bearing into t-case,
drop on rear spacer sleeve & thick washer,
zap big nut onto end of transmission shaft,
tork 5 bolts to spec.

Still not done, waiting on various rubber boots and a p-brake cable to come from toyota. Parts were shipped days ago, supposed to be delivered Friday or Saturday, but still not here.

Stupid holiday shipping rush, messing up my build.

 

[FJ40Jim]

Got the tranny assembly demounted from the special assembly jig. Just waiting on rubber parts & a p-brake cable to come in the mails before it's ready to install.

Got a 1965 June temp sender unit from Pardion (Thanks!)

and sent him this correctly assembled FJ25/40 fuel pump:

Next stop: clean & paint bellhousing, mounts, clutch fork.

 

[FJ40Jim]

Tech info needed:
Is the 1962 oil pressure light switch a blade terminal, or a Toyota button style terminal?
FWIW, all the gauge OPSU have button terminal, but dunno about these, and can't tell from the wiring under the hood, which is bit messy from previous V8 swap.

Edit- pic of button terminal

And a blade terminal:

 

[Splangy]

1962 would be button style

 

[FJ40Jim]

Thanks Splangy. Button style on order now.

Tranny/transfer rubbers arrived from Toyota yesterday.