Builds Gr80 Build

[Napster]

Sooo... my 40th is coming up and I want to do a big trip but the pig is in pieces. I am not sure how I talked my wife into it but I figured I should buy another rig! Newer, but since I have a small budget I was shopping for something that needed work. I was open to 4runners, Tacoma, fj80, fj60, 100, or a Lexus gx470. I scoured the internet for something I could afford but wasn’t too rough. My wife had great advice and said I should be patient and get what I want. After 3 months of looking I found the perfect rig. 1991 fj80 with 138k miles, clean body and interior but “needs a head gasket” called the guy and set up a time to go look. It was a 4 hour drive and I get there and it was not quite as clean as the pics but still pretty good. Paid the man $2500 and towed it home.

 

[Napster]

Basic idea is to get it baselined, and ready for a trip in November. I originally purchased it in August. The first order of business was to figure out if it really needed a head gasket as 138,000 seems too early for that. The story was, the PO bought it for his daughter and it started over heating on long hills. He threw a new radiator at it and it kept getting hot. Then a buddy of his offered to look into it and started taking it apart. And then it sat for 6 years! When I went to buy it I looked it over and luckily the intake/exhaust and head were never touched. Basically the accessories were removed and the the guy gave up. The PO handed me a box of parts including a new water pump

For the 4 hour trip home all I could think about is all the parts that were going to be missing.

At home I check the oil... no coolant in the oil. I decide to just put it back together and see if I could get it running and then go from there. I lay out all the parts and start putting the puzzle back together. Less than 24 hours later it’s back together and I’m only missing 4 bolts. Since it was sitting so long, I decided to drain the gas. 20 gallons of nasty gas came out...

5 gallons of fresh gas, new battery and six cranks and it fires right up! No white smoke. Idles smooth. While putting the fan clutch on I noticed that there was some oil on the outside... once running and warm, the fan seems to be turning way too slow... could the “head gasket” really just be a bad fan clutch?

I order some oil for it and refill it. Take it for a test drive up a long strap hill and it runs perfect. Easiest head gasket I’ve ever done!

 

[Napster]

Next problem is to get it smogged but it runs so well I figure let’s just get it tested. I threw some new spark plugs and a cap and rotor on it and take it to the smog shop. Thing passed with no issues! I know what you are thinking, “this is too good to be true”

Just wait...

 

[Napster]

With my smog certificate in hand I head for the dmv. Turns out it’s not on Non-Op as the previous owner stated and I owe 6 years worth of back fees. I talk to the lady behind the counter about how it’s not my fault etc. she was super nice and waived all the penalties so I just owed $400 which still puts this rig in the good deal category.

 

[Napster]

Now that it is officially in my name it is time to look it over and see what needs to be done:
Tires and wheels
Front axle rebuild
Stereo is useless
Passenger side window
Peel the purple window tint
Windshield wipers
Engine resealing

What I would like to do over time:
Bumpers
Roof rack
Modular storage system for the back
Lighting
Communications

I am not building a crawler but more of an adventure rig. Something to explore with. The biggest issue with the 80 is fuel mileage so I would like to convert to manual hubs and explore engine options.

 

[Napster]

One of the gifts of the previous owner is that the entire rig is filled with wasps! My son got in to go for a ride, closed the door, and all hell broke loose. Luckily the windows were up and they were outside. Had to take the mirror apart to clean it out.

 

[Napster]

Put it off for a bit but finally started the Front axle rebuild. Bought a front axle rebuild kit from Marlin Crawlers. Its a messy job but now I have new brakes, wheel bearings, trunnion bearings, seals and fluid in the front axel.

 

[Napster]

The front door speakers were shot and the display on the original head unit was non functional so I needed to update. Had an old Sony deck laying around and bought some low profile Infinity Reference 6-1/2” speakers. They were the only thing I could find size wise that would fit in the doors. Only $45

 

[Napster]

Next is resealing the engine. I replaced the valve cover gasket, lifter cover gasket, timing cover gasket, and front seal. After cleaning the lifter cover some factory markings became visible. Not sure why but it made me smile. Anyone know what these mean?

I will need to do the rear main seal at some point but it is not leaking too bad and so it will have to wait until after the trip. I tried using the starter bump trick to remove the crank bolt but It would not budge. So I made a crank pulley holder and pulley removal tool in one.

 

[Napster]

Major day! I bought tires:
General Grabber x3 285/75R16

What came on the truck were 33x12.5x15. I debated about keeping the 15in rims but all the tires that size had a lower load rating (C). As 80's are heavy to begin with, and this thing is going to be loaded with people and gear, I decided to move up to 16in rims. I really like the look of the Toyota steel spares. After doing some digging the 1996-2002 tacoma and 4runner had 16x7steel rims for spares. I found one rim at the local auto wrecker for $35 and painted it up to see if I like it

Turns out I like it. Got rid of the 1990's blades and balloon tire look and gained the more industrial look of the black steel rim. the rim and tires are narrower and the offset of the steel wheels places them more in the stock location. This means less mud on the side of the truck and you know ih8mud!

Now I just need 3 more rims...

 

[Napster]

Fixed the passenger side window, it was just a window switch.

Replacing as many radiator/heater hoses that I can get my hands on.

Rebuilt the power steering pump as the front seal was leaking.

Also, on a totally cosmic level: the yakima racks in the original post were included in the sale because the PO could not find the key. When I got home I tried my key that I have had for 10+ years and it fit. So either you believe in destiny or yakima needs more key combinations!

 

[SoCal80series]

Nice write up. I enjoy these type of builds. Will be subscribing. I just wish I had your mechanic skills!

 

[Napster]

Nice write up. I enjoy these type of builds. Will be subscribing. I just wish I had your mechanic skills!

Thank you! I’m along for the ride too!

 

[White Stripe]

Nice cruiser. Cool head gasket story haha.

 

[cruisermatt]

Nice deal. Some people should not work on cars. I always liked the 91-92 two-tone 80's the most. Looks good with the steelies.

 

[Napster]

Got it all back together and now I am sure the oil pan gasket is leaking. One is on the way. There is a new bounce in the Gr80’s step after adjusting the valves, timing, new plugs, cap and rotor, and a new air cleaner. Idles smooth accelerates well for the slug it is and even sounds good exhaust wise. Speaking of exhaust... one of the only complaints I have now is an annoying rattle at idle. The exhaust is hitting on the back of the transfer case. Someone redid the exhaust and did not take much care. I am not sure what the original routing was but it is currently crazy! Currently it crosses over the top of the transfer case to the other side of the truck... which seems weird...

On the bright side, I get to drive it again! Got the racks on it and went for s ride.

 

[mjosoba]

Very partial to that year and color as it was my first 80.

 

[Napster]

Total wheel fiasco. I am trying to piece together a set of 16" spares off 96-02 4runners. Found one at the local auto wreckers for $35 which was a score. Drove 1 hour to pick-n-pull and struck out. Looked at ebay but shipping made them seem over priced. Found some new reproductions on amazon for the same price. The load rating was 2,160 lbs so I ordered 3. Finally arrived and they look different than the pic (not the end of the world) but the wheels and box are labeled with "max load 1400 lbs" I hate shipping things back but since the the load rating is almost 1000lbs different I think I am going to have to. Ended up ordering 3 used wheels from 3 different venders on ebay... heres hoping they arrive before I leave for my trip.

In other news, I took my son and his friend fishing to a lake up an hour long dirt road. Love the way the 80 handles dirt and stoked to have a rig to get out and about with!

 

[Napster]

Finally got the last of the wheels sourced. Ended up buying off ebay for about $75 each after shipping. Did some sanding and painting today and will try to get the tires mounted up tomorrow.

 

[Napster]

Long day today. Spent the morning doing the oil pan gasket. All went better than expected. Only had to remove the tie rods to get the pan off. I had a 3 piece gasket which I was not excited about. I used gasket cinch to hold the sides to the oil pan and some silicon gasket maker to hold the half moon pieces to the engine block. Went on easy.

Mounted the tires to the wheels and balanced them. Got them all mounted to the cruiser.

Changed the oil filter and filled with oil.

Started it up and no oil leak... for 30 seconds and then... oil leak is the same. Fug. I have this sinking feeling that the leak is the seal between the front end plate and the block. Which means pulling the cam. Spent some time looking around with the engine running and figured out that the leak is coming from above and leaking down to the front of the oil pan. I started thinking that the oil leak got way worse after I did the timing cover...