Builds HELLO, MY NAME IS CLARK - FJ62 docu-series thread

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(Clark is the FJ62's name... not mine :steer:)

This thread may be a bit late on the start, as the subject FJ62 has already been a part of the family fleet for 3.5 years at this point! The 5th Toyota I’ve owned, Clark was a Craigslist find in Tucson, pretty much completely stock, and has been an AZ truck its entire life. 240k when I picked it up, and after some idle adjustment, passed emissions here in Phoenix with no issues. It was basically just a second vehicle / daily driver for the last few years, as my main camping truck was a 1997 4runner I got in 2002.

But the camping rig of 20 years (!) was picked up by its new owner this morning and has already been spotted in Amarillo Texas as of this evening...

So Clark is now front and center for some attention. Based on 30 years of working on Toyotas and almost 20 years of figuring out what works best for me in an offroad 4x4, I have a list of parts & plans in mind with our sights set on another 20 years of camping & exploring.

The thread intention is twofold, partly to share info and progress for anyone that may find interest, and part for me to document & remember things I've done. I never did a build thread for my old truck, and after 20 years I've forgot a lot of details that I didn't document.

A few pics from our first adventures together in stock form... but capable nonetheless...

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Near the Verde River in AZ 2018
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Quick overnight campout somewhere near Red Creek. 2019. @bwesty hanging out too!

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At KOFA on the 2018 Relic Ride (thats not a real thing, just some rad camping buddies with cool older rides)


Done list:
  • All new 555 steering rod ends, drag link & OME dampener (Cruiser Outfitters)
  • New brass CSF radiator (it's leaking...again...)
  • AISIN water pump, thermostat
  • Rear heater bypass
  • Exhaust & muffler replaced - Scottsdale Muffler
  • Front Crank seal replacement
  • Rebuilt Starter w OEM parts
  • Install Auto Meter 2635 temp gauge
  • Repair blower fan - replace brushes
  • Split radiator shroud
  • Refurbish battery tray
  • Fixed High Idle / Stumble / Misfire
  • Install BlueSea USB port
  • Fixed wobbly shifter
  • Replaced steering box input seal
  • Reseal roof gutters
  • Tune up / timing / belts / all water hoses
  • Dobinsons lift with IMS shocks
  • Fabricate & install roof rack - mount iKamper
  • Brake lines & Brakes

To-do list

  • Deep Cycle battery (X2 Power Premium)
  • Aux Fuse box
    • aux 12vDC power box at cargo area
  • Install Smittybilt Console
  • Headlight upgrade of some sort
  • Front axle rebuild
  • Replace washer fluid reservoir (thanks @bwesty!)
  • Replace window & door seals
  • Replace stereo & speakers
  • Front winch bumper (install M8000 from my old truck)
  • Install HAM radio
  • H55 swap
  • Replace carpet & install Dynamat
  • Rebuild 3FE (have a spare)
  • Repair radiator leak (again)
  • 16" rims & 235/85/16 tires (maybe... I kinda like the 31s on it now)
  • Rear locker (ARB or Harrop)
  • Interior camping setup
  • BMW leather front seats
  • Air compressor ??
 
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Ughh... kinda hate looking at that to-do list... seems so long!

Well... got the Dobinson's lift installed. I like the parts... but had a few frustrations...

First... Dobinson's doesn't mention or offer a front axle pinion angle shim when you order the kit. This was a problem, and I didn't realize it until after the kit was installed. Shame on me for not doing additional research, but shame on them for listing the kit as "complete", when it isn't. At the very least they should mention that you *may* require a shim and probably should have them (and center pins) on hand at the time of install.

Second... the rear driveshaft was too long after the lift was installed. By about 3/4". Took it to Phoenix Rack and Axle on the way to the airport for a flight out, and picked it up on the way home. That was convenient. Until I started driving the truck and the driveline vibration was horrendous. D*mmit. So another 20 mile round trip downtown to PR&A... this time they threw it on the balancer while I waited. They added quite a few weights to the driveshaft... so I'm pretty darn sure they either forgot or just flat didn't balance it the first time... lesson learned... if there are no weights on your shaft when you pick it up... have them check it to be sure. After the second attempt, the truck is now drivable. I still think the driveshaft could be balanced a bit better... but it'll need lengthened when I install the H55 so I can live with it until then.

After that, one of my front calipers decided to blow a piston seal and puked all over the wheel. Probably because I was pushing the pedal so hard to stop after the lift was installed for some reason... well later I realized it was probably because the LPSV was outta whack from the lift... there'a another thing Dobinson's doesn't mention. I fabricated a 2" lift bracket for the LPSV arm, and added another inch with the adjuster... getting close to where it should be. So while I was ordering up calipers, I got a set of SOR extended steel braided brake lines. Got that out of the way. Still need to dial in the brake bleeding a bit better, but it's drivable.

Got a camping trip this Weeknd and all the work has been to try to get the truck dialed in for that.
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Built a roof rack yesterday and today. Got some pics below. All installed, and got the iKamper up there just before dinner. The rack will need to come back down for some mods and paint (or powder coat). I used 1x1.5" .125 wall steel. The rack weighs bout 68 lbs, but I'm pretty sure 2-3 people could stand on it with no flex. I used FrontRunner feet, can't say I love them but they'll do. When I was planning for the feet, I looked at Frontrunner's site and their 60 kit comes with 2 different size feet. the front 2 are about 30mm taller. So thats what I bought. But in reality, I didn't like the front taller, and there's plenty of roof clearance using the 4 shorter feet. So I'm going to just get 2 more of the shorter feet for a total of 6.

I'm simultaneously building a 24' RV gate... it turned out to be useful as a welding table for the roof rack =)
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Test fit
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Here's my helper...

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iKamper mount clamps are pretty sweet, but I neglected to check if they'd fit 1x1.5" tube before I planned the build... turns out... they don't! Thankfully only about 1/16" of material needed clearanced on the 1/8" wall tube. I'll plan to tub that area after this trip. I should have installed those 2 tent mounting bars so the 1.5" section was horizontal rather than vertical. Oh well... next time.


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So here we are with the lift, roof rack and iKamper installed. There's a 26" x 48" area behind the tent that I'm planning to use for additional gear... either a gear box, jerry cans, expanded metal base, or some combination of that. No swing out bumper planned, so I'm pretty sure my spare fuel will be up top there behind the tent.
 
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Looking good so far! I'll be watching for your transmission swap.
I used to live in Phoenix. I sure do miss the vast amount of public land out there! Not a whole lot on the east coast.
 
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Clark…excellent “minimalist“ rack to support your individual needs…nice design and engineering approach.
Thanks! Yes that was exactly my approach. I like working with steel as it's easy to re-configure later if needed. Here's a lousy pic of it just before I ground the welds smooth then mounted it up...
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Had a chance to get out with some friends this weekend and put the suspension to the test for the first time... I'm impressed! I think I finally realized something that a lot of folks (maybe everyone?? haha) understood previously... which is... the LandCruiser really excels at traveling in difficult environments even when severely loaded down. My previous truck (1997 4Runner) always got me where I wanted to go and back, but when it was really loaded (fuel, water, full fridge, tools, gear, 2 adults, dog, and later with the rooftop tent), it struggled with the weight. This weekend I had 90% of what I have previously carried to Baja for 10 days loaded up, and I don't think the 62 sagged an inch or bottomed out once on the severe washouts we encountered. Not to mention it was a very smooth ride, which I was a little concerned about, coming from an IFS truck with Icon coilovers up front and coil sprung rear.

The negative - my mod list is getting longer :bang:
 
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Photo Mar 30, 18 02 49.jpg


Started a separate 3FE rebuild thread for a spare engine that will eventually get installed into Clark.

 

rghouse

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The 60 is looking great! After my first extended off-grid trip in my 3FE 80 I came away with the same astonishment in regards to the smooth and easy ride a Land Cruiser wagon can provide. Truly amazing how they handle long, rough roads with tons of gear and people loaded on.
 
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I failed the emissions test for high NOX in Phoenix (Maricopa county). Limit is 4.50, first test blew 4.95

I don't have a vacuum gauge to check much on the EGR system per the FSM, but a quick blow by test of the EGR VSV indicated it was failed (when 12v is applied, should be a closed valve - mine remained open regardless of 12v or no voltage). Interestingly, checking the ECU for codes revealed none.

Lucky for me I have a spare 3FE engine and all the emissions stuff with it... the spare VSV tested good... so I installed it.

Today the truck passed emissions and NOX registered at 3.84

All readings:
HC 0.62 (limit: 3.00)
CO 20.89 (limit: 25.00)
NOX 3.84 (limit: 4.50)

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