Fluid Replacement FJ40 1977

Discussion in '40- & 55-Series Tech' started by ptefj40, Aug 10, 2018.

  1. ptefj40

    ptefj40

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    Hi All,

    I decided to do a fluid replacement whilst I have the transmission hump in the shop for repainting. This is the truck that I bought in pieces from NC.

    I managed to get the fluid drain plug out on the transmission and the transfer case. The fill plug is completely gnarled on the transfer case BUT I got the breather nut off with a 27mm socket - phew!

    In the process of draining the transmission, the old oil is white, milky and horrible. I've let both the transmission and transfer drain for 1/2 a day or so.

    Couple of question and advice.

    1. Can I fill up the transmission with new oil, or is there any other flushing of the system I ought to do before refilling with new gear oil?

    2. Can I refill the Transfer Case with new gear oil via the breather hole at the top with the correct quantity? I found on the board that the TC without PTO takes 1.8 quarts.

    3. Assume the only way to get the stripped fill hole nut on the TC is to weld a nut to it and heat/ice it?

    Help appreciated!

    Best, Phil.
     
  2. fj40cruisin

    fj40cruisin

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    I don't know about any flushing system but I think you should look into it. Having that color of oil would make me weary. As for the fill plug, I had the same issue. I couldn't get mine off because it was so stripped. I ended up buying a Knipex 8701250 10-in cobra pliers. This tool gets tighter the harder you turn. I think they are on Amazon for $30. It eventually came off and I replaced the plug. You can also try heating the plug. When I completely drained my tc it actually took over 2 quarts of oil. I filled it until oil started oozing out the fill plug then I screwed on the plug. Hope this helps.
     
  3. ptefj40

    ptefj40

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    Thanks!! I just ordered a set of the magic pliers! Be here Sunday!

    Do you happen to know the size of the fill plugs? I think there was talk of them being replaced with Allen wrench style. Did you do that?
     
  4. subzali

    subzali

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    Just get a replacement plug from the dealer. Doesn’t have to be hex up high like that, the hex is for drain plugs that scrape on rocks typically. I would say just fill and go.
     
  5. GA Architect

    GA Architect SILVER Star

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    FWIW - I just replaced all the old drain & fill plugs with new 90341-18021 allen head magnetic plugs on both diffs, transmission and the transfer case. Along with the new allen head plugs, all steel units (diffs & tranny) get steel gaskets (12157-10010) and the aluinum T-case will get the auminum gaskets (90430-A0003).

    [​IMG]
     
  6. fj40cruisin

    fj40cruisin

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    I just got Toyota fill plugs from SOR. I believe they were 24mm socket.
     
  7. ptefj40

    ptefj40

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    Thanks guys, just went down to my local dealership and ordered the parts...easy! I also got the Yankee Toys discount rate. Each plug was 2.44 each and the crush washers just over a buck apiece!
     
    swelltimes and GA Architect like this.
  8. swelltimes

    swelltimes SILVER Star

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    Lots of folks in the greater Boston area who could help you out with wrenching and advice as you work through tasks on your truck - just post up on the YankeeToys section!
     
  9. sproggy

    sproggy SILVER Star

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    What's this YankeeToys section? Where is it?
     
  10. swelltimes

    swelltimes SILVER Star

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    Yankee Toys is a group of Toyota nuts in New England: MA/NH- Yankee Toys
     
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  11. sproggy

    sproggy SILVER Star

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    I'll check it out. Thanks
     
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