Builds Hygge's Sawdust FJ62

[hygge]

As of now I am cleaning and cleaning.

And attempting to keep the shims in order, since I do not have the SST. I plan on putting everything back together the way I found it (but much cleaner and with newer parts where necessary).

 

[hygge]

Oh Yeah and here are some of the parts I decided to buy which seem like a good idea, but perhaps not 100% necessary.

The hard line between the brake caliper to the dust shield is actually only $5.54 and still available. Bought one for each side.

Decided as mentioned above to also replace the front outer soft brake lines. I debated about just getting all of this from rockauto or amazon, but decided to go OEM. If the original brake lines lasted 30 years with no issues, it seems like a reasonable cost to keep things original. I also looked at Slee and Manafre for stainless steel brake lines. Maybe I'll go that route eventually.

I bought the axle soft brake line for both the front and rear to round it out and new clips for the brakes.

Since no Toyota order is complete without buying other things, I decided to replace some of the bolts as part of the knuckle rebuild and get some differential plug gaskets.

Parts Numbers are below.

Order Contents:

P/N Quantity Price EA Description
9008011225 2 $ 1.10 BOLT, WITH WASHER
9164180616 12 $ 0.87 Engine Coolant Pipe Bolt
Bolt, with Washer.
9694033805 1 $ 43.05 Brake Hydraulic Hose (Rear)
9694033005 1 $ 40.64 Brake Hydraulic Hose (Rear)
9694039855 2 $ 37.97 Brake Hydraulic Hose (Front)
1215710010 4 $ 1.20 GASKET; PLUG
9699110080 4 $ 1.42 CLIP
4734360021 1 $ 5.54 TUBE, WHEEL CYLINDER, FRONT LEFT NO. 1
4734160031 1 $ 5.54 TUBE, WHEEL CYLINDER, FRONT RIGHT NO. 1

 

[joebattle1]

Kristian, are you doing the knuckle job by yourself?

 

[hygge]

Kristian, are you doing the knuckle job by yourself?

Yes @joebattle1 !

 

[hygge]

Once the kids and wifey get to bed, its time for me to get to work. Usually this is around 9:30pm. Its about 1:15am now, so probably a good time to call it quits, since I have work tomorrow.

Tonight I finished disassembly of the knuckle's lower bearing caps, the passenger-side hub, drilled out two broken studs and tested out my new shiny Harbor Freight ultrasonic cleaner.

Drilling out broken bolts is never fun. Its tedious and easily screwed up. I was able to get two bolts out. One from the Hub and one from the Oil Seal Retainer ( on the back of the knuckle). Luck was with me tonight and I am rejoicing.

I bought a cheap $70ish Harbor Freight ultrasonic cleaner last Friday. I would ideally like to get a parts cleaner station or a media blasting box, but I do not have a garage or space for it. I have a small shed and its packed with too much stuff as is. So this 2.5 Liter HF solution is might current thought around how to speed up cleaning of parts.

The HF cleaner works decently enough. Its not perfect and its not that big, but it can take in hubs, the Steering Knuckle Arm and other misc truck parts. I think putting it on the longest setting of 8 minutes is useful in my limited experience. Also if you take a moment to clean off some of the gunk before dropping it in that will help. I give it a B - so far.

Next up will be cleaning up the dust shields, a little more knuckle cleaning and finishing the driver's hub cleaning. I might spray paint the knuckles. We will see how much time I have.

Then the re-install can commence over the next coming nights.

 

[joebattle1]

Once the kids and wifey get to bed, its time for me to get to work. Usually this is around 9:30pm. Its about 1:15am now, so probably a good time to call it quits, since I have work tomorrow.

Tonight I finished disassembly of the knuckle's lower bearing caps, the passenger-side hub, drilled out two broken studs and tested out my new shiny Harbor Freight ultrasonic cleaner.

Drilling out broken bolts is never fun. Its tedious and easily screwed up. I was able to get two bolts out. One from the Hub and one from the Oil Seal Retainer ( on the back of the knuckle). Luck was with me tonight and I am rejoicing.

I bought a cheap $70ish Harbor Freight ultrasonic cleaner last Friday. I would ideally like to get a parts cleaner station or a media blasting box, but I do not have a garage or space for it. I have a small shed and its packed with too much stuff as is. So this 2.5 Liter HF solution is might current thought around how to speed up cleaning of parts.

The HF cleaner works decently enough. Its not perfect and its not that big, but it can take in hubs, the Steering Knuckle Arm and other misc truck parts. I think putting it on the longest setting of 8 minutes is useful in my limited experience. Also if you take a moment to clean off some of the gunk before dropping it in that will help. I give it a B - so far.

Next up will be cleaning up the dust shields, a little more knuckle cleaning and finishing the driver's hub cleaning. I might spray paint the knuckles. We will see how much time I have.

Then the re-install can commence over the next coming nights.

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Kristian, if you need to borrow my parts cleaner or my steamer let me know.

 

[hygge]

Thanks for the offer @joebattle1 appreciate it. One of these days I might take you up on that. I think at this point I am pretty far along in the rebuild. But damn, its been messy like everyone always says it is.

Luckily there is light at the end of the tunnel.

 

[hygge]

Its amazing how 30 year old parts can go from the grossest, disgusting pieces of metal in the world to works of engineering, Japanese works of art. It takes scrubbing, cleaning power, some time, paper towels ( sorry trees), degreaser - but oh does it look pretty.

Also got my new OEM parts from Toyota. Excited to finish up the rebuild (hopefully by the end of the weekend).

 

[hygge]

Methodically rebuilt my Aisin Manual Hub tonight. It probably took me a good hour to get the first one done, despite some awesome youtube videos and print outs of the FSM. The second one only took me about 15 minutes.

All in all, a good little project and happy that I know can talk about Aisin hubs like an expert. One thing I did not have, but wish I did were replacement plastic seals that go around the dial. SOR has these part of their kit, I didn't buy their kit. And at this point too late to go out and source new ones from Toyota or aftermarket.

Decided to not repaint the Dial. I mean, who cares. Its just going to get dirty.

One step closer to finishing up the knuckle rebuild. Jeez, hard to believe that some folks bust this out in one day. Are the folks doing this in one day Superman or just not breaking everything down to a million pieces like me?

 

[hygge]

Hitting a bit of a wall today. I can’t seem to get the axle separated from the birfield. I have been using a brass drift to hit the inner bearing. I even tried some propane to heat things up.

Any best methods? I don’t want to destroy the c-clip since I need to reuse it during the rebuild.

At this point there’s is no going back since there are a tone of pieces of chipped brass drift inside the birfield joint.

 

[fjbj40]

Here is the way Separating and reassembling the birfield and inner axle assemblies

 

[joebattle1]

Kristian, You get it separated yet? Here's a good vid.

 

[hygge]

@joebattle1 I've been trying since late last week to slam them apart with 1 1/2" PVC pipe. It's not being friendly, but is chilling where the birf hits.

I feel like the pipe needs to be metal. The PVC absorbs most of the vibration.

Seen this video with wheelie Pete and powermodz.

Thanks for sharing!

 

[SteveH]

Use a steel pipe and buy a new C-clip from the dealer. I think the PVC pipe is indeed absorbing the energy.

 

[hygge]

@SteveH and @joebattle1 So finally I got'er done. It took a trip to Home Depot and finding a 1 1/2" galvanized steel pipe that happened to be cut to about 3' long that had been pre-cut. They only sell 10' sections for $50, but the store manager sold it to me as though it was a 1-foot piece.

I brought my axles with me, since slamming them at home after 10pm in the driveway is frowned upon by my sleeping children and neighbors.

For $14 to buy the pipe I finally got the damn birfields dislocated from the axle shafts. Victory!! I had bought replacement circlips last week from Toyota so I'll be good once I rebuild everything.

Decided to rebuild the calipers since they look like hell. Bought a kit off of rockauto that should arrive on Friday.

Hoping I can finish everything up this weekend. Fingers crossed!!! The end of the knuckle job appears to be approaching.

 

[hygge]

Since you are limited to five images, here are a few more of the calipers.

Did I mention that while this FJ62 has been AWOL, I still got to go to Turf N' Surf 2019 last weekend in Pismo Beach and rock out with my 99' LC?

New video by Kristian Hansen

photos.app.goo.gl

 

[SteveH]

Nice job on the birfield!

I found that blowing out the 4 pistons on my FJ40 calipers was quite a challenge. I ended up reinstalling the brake pads in the caliper so that all 4 pistons 'came out' about the same amount at a time (before any came fully out) when I applied air pressure. If you don't, you will likely find that 1 piston pops out early, leaving 3 stuck in their bores. Your goal with the air pressure is to get all the pistons about 95% out of their bores before any single one pops out. Good luck with that!

Once all the pistons are out, the actual rebuild is easy, of course, if messy.

 

[joebattle1]

Kristian,

Are you going to wheel the 62, put big wheels on it? Have you considered upgrading to chromoly birfs/axles? I sort of wish I would have done this when I did my knuckles. Just for piece of mind.

 

[Borrego]

I really like reading through everything you've been doing! Great write up!

 

[hygge]

Kristian,

Are you going to wheel the 62, put big wheels on it? Have you considered upgrading to chromoly birfs/axles? I sort of wish I would have done this when I did my knuckles. Just for piece of mind.

Great question. While I have thought about doing that (Low Range Offroad/Nitro), its not in the budget for the moment. Maybe over time.

For right now I am sticking with my original tires (BFG 31.5"). When I upgrade, I'll likely go for Falkens that are 32". The next big purchase will likely be some sort of OME or other lift kit. I'd like new shackles, springs. If I had a spare couple grand, maybe . axle upgrade would be in there, but more likely I'd go with a rear bumper with swingout.