fj80 and lx450 ps pump rebuild (1 Viewer)

[gnob]

glad to hear it was an easy fix.

 

[skw6r]

so at this point the pump is totally disassembled. take a few minutes to clean it all up with solvent or brake cleaner. take a break for a frosty beverage if need be.

so the rebuild starts with installing the new front seal. this is a double lip seal but still needs to be installed the right way.

use a socket to install the seal. the seal needs to be at the bottom of the pocket, notice the reveal above the seal to the front of the pump. according to FSM it should be 3.4mm below the lip.
View attachment 502766View attachment 502767View attachment 502768

Working on replacing this seal, however the replacement seal seems to be about ~1mm too small to sit snugly like the OE seal did. Am I doing a step wrong? 1994 fzj80 using 04446-60080

 

[gnob]

Working on replacing this seal, however the replacement seal seems to be about ~1mm too small to sit snugly like the OE seal did. Am I doing a step wrong? 1994 fzj80 using 04446-60080View attachment 3760602

View attachment 3760608

if the seal is a different size than what came out, it's the wrong seal. the old seal should have a number on it. it's possible the seal kit was packed wrong. any possibility you have a remanufactured pump?
that part number for the kit should be correct for all 80/LX

 

[skw6r]

if the seal is a different size than what came out, it's the wrong seal. the old seal should have a number on it. it's possible the seal kit was packed wrong. any possibility you have a remanufactured pump?
that part number for the kit should be correct for all 80/LX

View attachment 3760616

Got in touch with the PO, turns out this is an after market pump

 

[gnob]

depending on which way you go from here, you can id/od that seal and get one from a parts house or bearing/seal supplier. i used Motion industries quite a bit.

 

[Sacred80]

finished PS pump ready to install

also the o-ring that seals the pump to the timing cover. it doesnt come with the rebuild kit.
View attachment 502801View attachment 502802

Thanks for the directions! I have a question:
What about this opening? Does it ever leak?

 

[alia176]

Thanks for the directions! I have a question:
What about this opening? Does it ever leak?

View attachment 3890210

You're pointing to a mounting hole that goes over a stud, and it doesn't leak.

 

[Sacred80]

You're pointing to a mounting hole that goes over a stud, and it doesn't leak.

That picture wasn’t clear and that opening isn’t a mounting hole. Look at this one:

 

[alia176]

someone else needs to chime in here 'cause I can't read this dude's mind

 

[Sacred80]

someone else needs to chime in here 'cause I can't read this dude's mind

I’ve added arrows pointing to the mounting opening where the studs fasten to the pump. That 3rd opening/hole is the mystery.

 

[cobrasteen]

I’ve added arrows pointing to the mounting opening where the studs fasten to the pump. That 3rd opening/hole is the mystery.

View attachment 3891044

That’s an aluminum plug. Usually a failure point on these as they age. This is what blew out on me during winter. Wits End used to sell an emergency one you could replace it with.

 

[Sacred80]

That’s an aluminum plug. Usually a failure point on these as they age. This is what blew out on me during winter. Wits End used to sell an emergency one you could replace it with.

Is my plug still there?

I finished my pump, reinstalled it and it’s not leaking anymore, so I’m hoping I don’t need to pull it back out.

 

[cobrasteen]

Is my plug still there?

I finished my pump, reinstalled it and it’s not leaking anymore, so I’m hoping I don’t need to pull it back out.

if you're lookin at it, its there.

If it wasn't there your ATF would have violently ejected itself from that hole. Congrats on completing the job.

 

[Sacred80]

Congrats on completing the job.

Thanks, Cobra. I appreciate some positive feedback.
It’s all extremely gratifying for me but not so much for the wife. “Is that black stuff under your nails permanent?”
I replaced the radiator, the power steering cooler, the harmonic balancer seal, the distributor o-ring, the oil pump cover o-ring and, of course, all the PS seals.
Last year I changed the valve cover gasket thinking THAT was the sole source of the Exxon Valdiz type spillage every time and everywhere it was parked. Poor, stupid me and my naivety.

 

[nkirsch]

Wonderfully helpful guide. Just finished my rebuild today. Only had minor grief pulling the different plates off

After rebuilding and reinstalling the pump, I am hearing a sound that I cannot tell if it is due to the rebuild or not. Any clue what this clicking/tapping sound could be?

My suspicion is the PS pump gear since it was what I just worked on and I cannot recall if this noise occurred before the rebuild.
How tight are the gear tolerances for this gear? If I am 0.1 mm too far out or in on one or both sides, will that cause issues? One tooth has a tiny nick on its face you can only feel with your fingernail. Could that be causing this?

 

[alia176]

Wonderfully helpful guide. Just finished my rebuild today. Only had minor grief pulling the different plates off

After rebuilding and reinstalling the pump, I am hearing a sound that I cannot tell if it is due to the rebuild or not. Any clue what this clicking/tapping sound could be?

My suspicion is the PS pump gear since it was what I just worked on and I cannot recall if this noise occurred before the rebuild.
How tight are the gear tolerances for this gear? If I am 0.1 mm too far out or in on one or both sides, will that cause issues? One tooth has a tiny nick on its face you can only feel with your fingernail. Could that be causing this?

if this tapping sounds didn't exist before the rebuild, then I'd remove the PS Pump and look at the teeth and see if one of them is nicked. I had a similar issue and it turned out couple of teeth were nicked. This was a pump from NAPA I think so I got an OEM unit and called it done.

 

[nkirsch]

if this tapping sounds didn't exist before the rebuild, then I'd remove the PS Pump and look at the teeth and see if one of them is nicked. I had a similar issue and it turned out couple of teeth were nicked. This was a pump from NAPA I think so I got an OEM unit and called it done.

Dang it, I do recall inspecting the gear after torquing down the nut and noted one single tooth had a nick on the face. Smaller than the damage you have shown, but you enough to feel it with a fingernail. Is it detrimental to drive with a tooth nicked like this, or does it not matter too much?
Would it be possible to file/smooth this damage off, or would that be a worse idea and possibly exacerbate the noise?

At worst, it seems like eBay has those gears available to replace (44316-60020).

 

[alia176]

Dang it, I do recall inspecting the gear after torquing down the nut and noted one single tooth had a nick on the face. Smaller than the damage you have shown, but you enough to feel it with a fingernail. Is it detrimental to drive with a tooth nicked like this, or does it not matter too much?
Would it be possible to file/smooth this damage off, or would that be a worse idea and possibly exacerbate the noise?

At worst, it seems like eBay has those gears available to replace (44316-60020).

i'd change out the gear but you can drive it in the meantime. It'll be annoying in the meantime. I wonder if you could file it smooth? Make sure this ebay is an actual dealership, otherwise, go straight to the dealer or an online dealer for this part. It's just too important and buying a repackaged OEMish sprocket would really piss me off.