fj60 problem. ant thoughts?

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fj60 problem. any thoughts?

We just bought an 1981 Fj60 from a board member and it seemed to be running EXCELLENTLY. Just had to change the fuel pump to pass inspection and replace a few vac lines. Here'e were the problem started.

About 3 days after the pump was changed and the truck had been driving great, it suddenly lost power on a main road after my gf shifted into 4th. We heard a loud clunk as if metel were hitting metal and as we pulled over to see what happened the engine idled irratically for about 10 seconds then stalled and was dead to the world. The tach kept jumping from 650 to 800 and then the truck died.

It was pouring rain and we were pulled over in mud so i couldn't get under the truck to see if something broke. The engine looked fine. Nothing appeared out of the ordinary. It seemed like the engine lost fuel flow or something. Is there something about the engine losing power that would cause that loud clunk?

We walked back a few hundred yards along the road to see if anything fell off the truck, but all we found were pieces of a Buick littered about the shoulder. We could not get her started for a few minutes, but as I was calling for a tow truck, gf gave it another try and the truck fired right up and seemed fine. We ended up driving her the few miles back home and took the trusty bombproof 62 instead.

Any thoughts? I am now noticing on test drives that when I let out the clutch while starting from stop, and shifting from 1st to 2nd, the truck loses power for just a split second, almost like she is going to stall, then picks right up and drives fine until the next gear shift. She seems to have less power on inclines when starting from stop as well and sometimes stalls. Because of this, driving on public roads is sketchy and she has been sitting in the driveway.

I have to say it was pretty embarrasing and frightening being stranded like that on a main road in a cruiser. Luckily we were not in the left lane.

I have not driven her more than a mile since the incident and am waiting for tune-up parts to arrive. wires, plugs, cap, fuel fiter, rotor etc.

Also, she just passed inspection at Toyota.

Any input is appreciated.:doh:
 
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Did you use an OEM or aftermarket fuel pump? Is the spacer block between the pump and block? Same problems occured with me when I first bought my 83 FJ60, and it turns out it was a bad aftermarket fuel pump (with no spacer block), which the PO put in, that was causing the problems.
 
fuel pump

Can you or someone, post a picture of what the pump setup is supposed to look like so I can compare? That would be really helpful.

The pump is OEM and was installed by Toyota at the time of inspection. Could they have installed it improperly? I am still waiting for my FSM.

The truck drove great for a few hundred miles after the pump was installed.
 
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My two cents

Is it necessarily your pump?

I recently had similar symptoms with my '87 60. The stalling out continued to get worse until finally I could not get her to start. I took it to my mechanic who said the problem was the distributor. He replaced the spark plugs, wires, cap and dizzy (got it used from another board member, thanks Andrew). It's been running fine ever since.

May be a completely different issue the symptoms sounded the same.
 
Possible vacuum leak? not sure about the total dying, but the miss sounds suspiciously like a leak.
 
I'm pretty sure there are posts on this board about installing a fuel pump w/out the spacer, and it's fine for awhile, then not fine. Guess the pump puts up with the missing spacer for awhile, then finally damages it.

If you look at the pump on the block, you should see a cast pump body, with a 1/4" or 3/8" resin spacer between the body and the engine block. If there's no spacer, you've found the problem. If there is a spacer, keep looking.

The noise you heard when it stalled is wierd though, I'm thinking it's related to the failure somehow. Just not sure how...
 
my 60 had the exact same simptoms and it was a very dirty/rust filled fuel filter. be sure to check this too!

Nicholas
 
spacer

Ok. I checked the pump for the resin spacer and it seems to be in place. Between the pump body and the flange and gasket assembly that bolts to the block there is an approximately 1/2 inch white-ish spacer about the diameter of a nickel.

I am waiting for a new OEM fuel filter and tune up stuff, so I really hope that helps. Maybe I'll run out to napa for an aftermarket filter in the meantime.

I'll let you know the results.

Thanks so much for all the responses to my problem.
 
I happend to have a new oem pump and spacer in the box waiting for installation. Here's some pics. The spacer is sold separate from the pump, but the spacer comes with the gaskets attached. These are for a 1985 FJ-60.
fuel pump 01.webp
fuel pump 02.webp
fuel pump 03.webp
 
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