FZJ80 in the UAE - repairs needed?

[Honger]

I picked up my 97 FZJ80 back in September here in the UAE. I've got a lot of the stock goodies I only dreamed of back in America. 2WD/4WD selectability, cloth seats, rear A/C, auxiliary tank, lockers, cooler box, manual throttle, rear-mounted spare, etc. It's a great rig and prior to me only had 1 owner, a Scottish guy who purchased it new and took good care.

I love this truck... its feels/handles a lot like my 98 T100.

Just took it to the shop for some work (downside of living here is that I have no garage or tools locally). Some questions for you experts.

When I'm doing slow movements and shifting from forward to reverse (think parking lots) I often get a clunk as I give it gas. The shop says this is an issue with the differentials and they showed me that both the front and rear driveshafts have a good amount of play in them (when you try to rotate them by hand). Does this sound right?

Secondly, they showed me that several of the bushings in the control arms (front and rear) have some cracks in the rubber. They wanted to replace the control arms outright. Isn't there a rebuild kit for these to just replace the bushings?

Thirdly, it was apparent that the diff fluid in the front axle has made it past the seals into the Birfields. I'm having the front axle seals replaced and the whole thing repacked. I've learned all about that from reading up on the site.

Thanks for your help.

Joel

 

[PDoyle]

sounds like a great rig. We need pics...

 

[lwfabs]

pics plz...

 

[Honger]

Ha! How'd I know that was coming. Sorry for the letdown, but here's the only pic I have right now of the beast. It's a newer car in the fleet... haven't even made it out to the desert yet. Never mind the Rover, that was an unfortunate mistake.

Can't wait to get it out in the desert for some glamour shots... like this one of my previous rig.

Any thoughts on my mechanical issues?

I'll post up a proper info/build thread in the coming weeks (once I get it back from the shop and out in the desert fun).

 

[Otamiway]

When I'm doing slow movements and shifting from forward to reverse (think parking lots) I often get a clunk as I give it gas. The shop says this is an issue with the differentials and they showed me that both the front and rear driveshafts have a good amount of play in them (when you try to rotate them by hand). Does this sound right?

If the "slop" or play is due to bad joints, when you turn the shaft you will be able to see the joint move separately.


Secondly, they showed me that several of the bushings in the control arms (front and rear) have some cracks in the rubber. They wanted to replace the control arms outright. Isn't there a rebuild kit for these to just replace the bushings?

Bushings are available in the US. A shop with a good press, should be able to press them out and the new ones in. They may not have the equipments.

Thirdly, it was apparent that the diff fluid in the front axle has made it past the seals into the Birfields. I'm having the front axle seals replaced and the whole thing repacked. I've learned all about that from reading up on the site.

Search for the many axle rebuild threads..consider doing other things while you are in there. Check your rotors, bearings and birfs to see if they need to be addressed.


Joel

Nice truck.. goodluck

 

[The Moe]

Secondly, they showed me that several of the bushings in the control arms (front and rear) have some cracks in the rubber. They wanted to replace the control arms outright. Isn't there a rebuild kit for these to just replace the bushings?

Thirdly, it was apparent that the diff fluid in the front axle has made it past the seals into the Birfields. I'm having the front axle seals replaced and the whole thing repacked. I've learned all about that from reading up on the site.

Thanks for your help.

Joel

Gongrats on this truck man, really nice... I too wish I have even half of these options here in the US.

I have owned/operated several LCs over the middle east... Both of these problems above are very common over there due to eccessive heat,dry and rough/bad road conditions... Mositure is the metal's enemy, heat is the rubber's....

IIRC you can optain all the needed parts for the second and third issues. i.e. the control arms bushings (rubber) can be sourced individually and of course, the front axel rebuild kit...

p.s. its always a good practice to replace the front rotors if they werent in a very good shape while the front axle job is performed, digging out a front rotor is about half way into the whole axle repack job...

Love the rig again....

RIP Tigris # 1 .... miss you...

 

[PDoyle]

Wondering if Beno or CDan ships that far away? If you search out these 2 names on the forum you may get OEM parts from a dealer a little less expensive, but ALL the right parts as well.

 

[OGBeno]

I will be shipping internationally soon.

 

[Offroads4x4]

How well do you know the shop? Are you sure its not just the U-joints and not the diffs? They clunk when worn out and will give you free play when stopped if you turn the drive shafts. If its just the u-joints it would cost you alot less.
Just an idea.

 

[Honger]

Thanks for all the help gents.

Regarding the driveshafts, I'm fairly certain it isn't the joints. I'm pretty familiar with bad u-joints and this didn't quite fit that bill. When the rotated the driveshafts back and forth the joints looked solid. So perhaps the differentials it is... what would be the problem?

Good to know on the bushings. I was SURE the bushings were replaceable. The shop guy looked at me like "hey, that makes sense!" when I suggested it. =) I'm fighting a mentality here that always seeks the path of least resistance and easiest work. Outright replacing the control arm is a LOT easier from their perspective than pulling the arm, pressing out bushings, pressing new ones, and remounting. Oh well. I'll see if I can source the bushings here otherwise I'll be giving Beno a call... I have a US forwarding address.

Regarding the axle rebuild, I've read through all the tutorials linked in the tech section so I'm familiar with what it takes... and what to expect. Just wish I was the one doing the job. I really miss the weekend tinkering and maintenance.

During the axle rebuild they are turning all the rotors and replacing the pads. Should I be outright replacing the rotors?

I know the shop pretty well, and trust the guys. The Filipino techs are extraordinarily competent and professional.

All this said... I'm going to check the ujoints again to be sure before I have them monkey with the diffs.

 

[1shot1kill]

Just get new rotors while they are in there!

 

[Honger]

Thanks again for all the input gents. I pick up the rig this afternoon and I'll be sure to snag some better photos and post up.

I've been digging around the tech write-ups and I'm definitely not convinced that the knocking that I have on start/stop and reverse/forward is a differential issue. I'll be going through some of the troubleshooting mentioned in this FAQ posting regarding driveline "clunk".

I reckon I'll be getting a LOT of use out of this site... a treasure trove of information and a great group of helpful people.

 

[PDoyle]

Sounds like greasing the drive shafts all 6 fittings is a good start.

 

[Malikov240]

Restored and need upgrades

hi there,

i have an FZJ 80 1995 ....its great offroading...it takes me everywhere...just needs more power ( horse and torque ) thinking of an exhaust system ...but i need it in a way where i can pass the police inspection every year...

the sound you get when shifting gears, i have the same issue..i was told to apply some grease on the shaft connection to the diffrential....i havent done it yet but when i do i will let you know if it works...it should reduce the nudge sound...but will see...

other then that i live in Oman....one day i will be driving dwn to UAE to look for work shops that can repair and upgrade my Beast.....

let me know if you know of any....

 

[Malikov240]

Anyone in UAE if you want to get togethor with our FZJ 80. that is possible....

i need an intensive chat...so i can start my upgrades...

you can contact me on +968 99011465 Only if your serious....

i'v had this beast for 17 years...its time to make a monster out of it....

regards,

Malikov240