HDJ81 1995 Rebuild

[Mufsalman]

Hello folks.. So I just rescued a 1995 80 series from a very abusive owner.. It hadn't been taken care of, so I got it cheap.. It's abuse had been masked by a somewhat s***ty paint job but the small rust was pushing through and peeling the paint as well as the tones of Bondo filler flaking off.. Having always wanted an 80s this is my first (cherry pop)..

Ok abit bout myself.. Pilot born and bred in Tanzania in Africa.. Get free time between contracts and hence needed to keep my hands busy..

Bought the rig and once all paper work was done I just couldnt wait to start stripping it apart.. I will keep this thread updated as I go along with my trusty mechanic to get the rig to great working order.. Or become broke trying..

I so for day 1 stripped as much of the interior as I could.. Pretty easy job.. The dumbass who painted it before broke half of all the trim pieces and door cards.. So now gotta source new ones or try to salvage the ones I have..

The car does have a bit of rust here and there.. Though underneath from initial inspection was clean.. Couldn't get all the way under the rig as I'm recovery from spinal surgery..

Please do chime in with tips, tricks and advice as I go through this..

 

[Mufsalman]

Tomorrow gotta go buy tools.. And start working on breaking down the front section

 

[Lumpskie]

I have a feeling this is going to be a fun thread. Keep up the good work.

 

[Mufsalman]

So day two didn't go as planned.. Work getting in the way.. Did manage to buy a brand new socket and rachet set.. My dad kept the old one.. .. Work will begin tomorrow..

 

[Mufsalman]

Back on the cruiser today.. Got an early morning start today.. Started out removing the seats..

Back seat..

Couldn't remove driver side front seat coz one of the bolts is completely rusted and stripped..

Removed the center console.. With my brand new socket set

Found some goodies in the jack pocket (tool hole).. If this is how the car has been kept then I'm in for trouble

Then started working on the front end.. Trying to remove the big bullbar.. Took of the light.. Which were quite nice.. I think they are the upgraded ones.. Look pretty.. Will clean and paint all the pieces am removing..

I did tape and label all wires so it be easier putting them back.. Did manage to break a few connectors.. They were brittle as f**k, but after 27years don't blame them.. So one more thing to add on the list of parts..

Haven't removed the bull bar yet.. Got one stubborn bolt and the sun was getting too hot.. (don't have a shade) so am indoors till the sun is a little lower down near the horizon..

 

[Mufsalman]

For the afternoon took out the slides which had been s***tyly installed.. That's when I found out the amount of rust thats down there .. Just below the door area is bad.. The rest is surprisingly good.. Favours the sellers story that the car had been sitting for a while..

Sooooooo yeah that needs to be fixed.. Got a quote for spare..
I was planning on overhauling the engine.. Meaning gaskets, rings and maybe pistons if needed.. Hopefully won't need to send the block for milling.. Fingers crossed..

So one pesky bolt decided it didn't wanna come out from the bull bar.. It was cross threaded and wouldn't budge.. Any tips guys?

 

[IanB]

That is a dusty truck!

You could try a nut splitter for the bolt holding the front bumper on.

I'd compression test the engine before pulling it apart unnecessarily, sounds like you'll have more than enough work here to keep you busy without that on top. These motors have a long life, what's the mileage on the truck?

 

[Mufsalman]

That is a dusty truck!

You could try a nut splitter for the bolt holding the front bumper on.

I'd compression test the engine before pulling it apart unnecessarily, sounds like you'll have more than enough work here to keep you busy without that on top. These motors have a long life, what's the mileage on the truck?

Odometer shows 110,000kms..but trucks coming into out country usually is wound back.. So I'd guess 190,000kms.. Educated guess.. That's why not taking any chances..

 

[Sarmajor]

That's not a Bullbar, it's a damage multiplier. Aluminium bars flex enough to allow panel damage. They also will remove flares if you bend the ends of the bar.

I have never seen anyone remove the side step like that. Were the bracket bolt to rusted up?

Keep this thread going. I have a hdj81 and will answer thing I know about.

 

[Mufsalman]

That's not a Bullbar, it's a damage multiplier. Aluminium bars flex enough to allow panel damage. They also will remove flares if you bend the ends of the bar.

I have never seen anyone remove the side step like that. Were the bracket bolt to rusted up?

Keep this thread going. I have a hdj81 and will answer thing I know about.

I don't think it's an aluminium bar.. It's just painted silver... It has a little surface rust in the back side of the bash plate and I remember aluminium doesn't rust from chemistry class..

Yeah the brackets have been welded on to the chassis.. Most of the street mechanics do that here cos a welder is cheaper to own n operate than a drill machine ..(that's why doing most of the work myself)

 

[Sarmajor]

There were factory studs and threaded holes for the factory step brackets.

It's a bonus if the bar is steel.

Just grind the head off the cross threaded bolt and the drill it out enough to get the bar off. Then you can sort out the holes without he bar in the way.

IIRC the factory bolts for the bars and towing eyes are a metric fine thread not the standard metric thread.

Grind the bolt off to release the front seat as well. Try not to damage the carpet. Protect it with a bit of metal sheet. Also watch out that the sparks from the grinder do not hit any glass.

Looks like the whole inside needs a damn good clean.

 

[Grant Woodbridge]

That is a 1HDFT motor. Bullet proof.
190 000Km is nothing. Do a compression test and let it be.
Your bullbar is a JDM Toyota approved bar and is very strong. I had the same cruiser with the same bar.
Great find keep the build going.

 

[inkpot]

Welcome to the party! Looks like a great project. Hope your back surgery was NOT due to an UNEQUALnumber of takeoffs and landings!!

 

[Mufsalman]

Welcome to the party! Looks like a great project. Hope your back surgery was NOT due to an UNEQUALnumber of takeoffs and landings!!

 

[Sarmajor]

Yes, as long as it has been serviced it should be good for at least 350,000km.

 

[jdayment]

Nice rig excited to watch the build.

 

[Mufsalman]

Today was a bigish day.. Managed to pull apart most of the major mechanical components..
Removed the turbo tube (pardon my lack of technical parts names).. On close inspection turbo fins are sound.. No signs of any damage or wear..heater core for the turbo was clean and oil free.. Removed all the hoses.. Timingbelt.. Accessories belt.. All need to be replaced.. Some tube (metal) lines are rusted to those need to be replaced..

I will need to find an air conditioning mechanic to have a look at the air conditioning unit.. I did find a few hoses left open and I don't wanna start bumbling around the manuals trying to figure out the AC system.. Might as well give it to someone who knows their stuff..

The brakes rotors are smooth and shiny.. Though did find the rear portion of air cooler fins to be broken towards the edge.. Not sure if u can spot that in the pic below.. Anyone with experience with something like this? Should I chuck them or keep using them?

For the front axle everything seems to be fine.. The grease was runny as expected from negligent maintenance of the birfield joints.. Bottom bearing was shattered.. Top one almost gone.. Gaskets and seals worn.. Glad I ordered the rebuild kit now

A little cleaning with petrol to remove all the grease and oil contaminants..

That's all for today folks.. Tomorrow will try opening up the top cover and oil sump as well as the diesel tank to clean out.. Wish me luck

 

[Grant Woodbridge]

That brake disc is poked. Also see if the inner pistons on the caliper are not seized. Looks like your discs are wearing more on the inside.

 

[Mufsalman]

For today opened up the top cover and sump.. And it was spotless .. Something seemed fishy.. Because I know it wasn't looked after that well.. Ow well, maybe I was wrong..

Opened up one of the conrod bearing and lo n behold.. It has a scrap running down the middle.. Looks like someone's cranked the engine over without oil for a while.. It wasn't too deep so put it back in.. Parts are costly enough.. Dont wanna add more on it already..

So the long wait for spares starts.. Ordering all gaskets, swivel rebuild kit, turbo Overhaul kit, all new belts, filters (oil, fuel and air) all being flown in from the .. It's turning out cheaper.. Let's hope customs doesn't hinder much ..

So in the mean time, it's cleaning time.. Sanded, clear coated and polished the headlight and indicators.. Spit shined the front grill.. And started cleaning and painting all the small trim pieces I tool out..

 

[Geert]

Aahh a HDJ
I have one myself. But mine is 25 years old and I have a 1HD-T (12valve)
I have done a pretty big restoration myself.
Maybe I can answer some questions that you have in the future.
Keep up the good work!