"HOW TO" replace rear sill FJ40 – STEP BY STEP (8 Viewers)

[DirtDauberGarage]

There are many threads about sill replacement here on MUD, but I could not find a comprehensive “step-by-step” guide on how to do it. Therefore, I decided to create one in hopes it might help someone.

A few disclaimers…

1. I am not a professional. I did this in my driveway with basic tools and a 110 welder. I am sure a professional body guy could suggest some ways to do it different or better.
   
   
2. I am not saying this is the only way to do it. Again, this is how I did it, and it worked well. I am sure there are other and maybe better ways.
   
   
3. Usually, you would need to replace the quarter panels at the same time, but @jesus888 wanted to keep as much original patina, so I only replaced the rust in the lower bottoms that was attached to the sill.

Here are some basic tools and materials that you will need…

• Angle Grinders – I purchase angle grinders from Harbor Freight using coupons, which allows me to pay about $10 for each one. I typically buy several grinders at a time so that I can have one equipped with a cut-off wheel, one with a flap grinder, and one with a grinding wheel. They usually last 4 to 6 years, after which I simply dispose of them when they die and buy new ones.
  
  
• Reciprocating Saw – This tool will be useful in tighter spaces that are difficult to access with a cut-off wheel. Make sure to have a sheet metal cutting blade on hand. If you have access to a small pneumatic reciprocating saw, that would be ideal, but it's not essential.
  
  
• Basic body working tools – Hammer and dolly to work the metal.
  
  
• Basic hand tools – Screwdriver, hammer, sockets, wrenches, pliers, etc.
  
  
• Spray Primer – To prime the bare metal.
  
  
• Drill and Drill Bits – Assorted drill bits to drill out spot welds, etc.
  
  
• Welder - You don't need anything fancy. A 110 MIG will work fine. I would suggest getting it set up with gas, especially if you are new to welding.
  
  
• Safety Gear - Glasses, face shield, gloves, earplugs, etc.

 

[DirtDauberGarage]

**Step 1:** Begin by removing any obstacles, such as the spare tire rack, rear doors, emblems, and so on.

• Keep in mind that the door screws may be rusted and difficult to remove. To help with this, use penetrating oil and a good JIS screwdriver specifically designed for Toyota screws. If the screws remain stuck, you can try using a vice grip. In some cases, my screws broke, and I had to drill them out and re-tap the holes.

 

[DirtDauberGarage]

**Step 2:** Next, remove the old body mounts located under the sill and attached to the frame. There is a total of four body mounts to take out. Here are some pics of the old ones and the new ones I replaced when I was done.

GIVE ME A FEW DAYS AND I WILL CONTINUE TO BUILD OUT THIS THREAD