Jim S. FJ40 Tuneup

[Tools R Us]

Inkpot and I are doing a project on Jim's '78 '40. It includes; 2FE, H41, split case and power steering change to FJ62 box. The motor, trans and transfer came from separate sources, so were missing significant hardware, etc. Most of the early work involved finding parts, would start on one job, only to find parts were needed, move to something else, end up needing parts, etc, so didn't take many pix.

In motor delivery, the dipstick tube was broken, so removed the oil pan to replace it, found an oil mod. It brought oil out of the pump through the pressure relief and used the old type external relief. Don't see the point, any advantage to it, so removed it. Were able to remove the tube that was epoxied into the pump cover and install the stock parts. Plugged all of the oil passage holes on the outside of the block, so there is no danger if parts coming loose inside the motor.

 

[Tools R Us]

The motor included a bored throttle body, that had a couple of problems. Someone installed the wrong TPS lever, so it didn't correctly contact TPS. Took some fiddling, got that resolved and the TPS properly adjusted.

The throttle body was bored, but not the plenum, what is the point in that?

 

[Tools R Us]

The head is ported, so spent some quality time with die grinders, cleaned up the upper and lower intake to match.

 

[Tools R Us]

The head gasket was not factory, so swapped for a dealer one. The "old" one was Stone brand, don't have any experience with them?

 

[Tools R Us]

The inside looks great, has coated skirt pistons, oversize stainless valves, mild performance cam, etc. We re-torqued all of the hardware, a couple of bolts moved.

 

[Tools R Us]

Also did a bunch of work that was not pictured, lots of parts cleaning, several rounds with the pressure washer, lots of parts procurement. Some dealer, from pick and pull yards, a bunch from Clonestocker, good guy to do biz with!

One of the big jobs was assembling the H41 and split case transfer. Some key parts were missing, Georg (orangefj45) came through bigtime on this one! Should have taken pix, but we were focused on doing the job correctly.

 

[Tools R Us]

This is how it looked the morning after it's final drive with the old drive train.

 

[Tools R Us]

Lunchtime shots, Mark brought pizza and filled out all of the injury and OSHA violations paperwork, turned out to be a lot of work, had to call in his backup Juan to help!

 

[Tools R Us]

Mid afternoon shots. Got the assembly out then stripped the parts that we will need off of it.

 

[Tools R Us]

That thing is so bad azz, even has dual power steering boxes!

 

[Tools R Us]

After another morning with the pressure washer, bring us to the next project, FJ62 power steering conversion.

Wanted to retain the stock shock tower and have it look as stock as possible. Took a bit of trimming to the tower.

The riveted frame is designed to flex. If it is not converted to a fully boxed, welded frame, it is not a good idea to make solid spots in it, or it will crack. So designed the mount to be somewhat "light" allow for flex, hopefully without cracking. Used DOM tubes through the frame, that sandwich the outside frame wall, then a gusset plate on the inside.

 

[Tools R Us]

Studied some of the factory mounts and attempted to replicate with some strength increase. The plate is the same thickness as the frame and only welded in stress locations, allowing for frame flex. Happy with how it came out, even used the stock, factory bolts!

 

[Tools R Us]

The next task was the steering column. It had a rag joint welded to the end of it, so out it came. Cut the rag joint out and disassembled the column.

Used a spline section from the pick and pull, in the lathe, put a taper and index snout on the end. Chucked up the column put a taper and hole that the spline end would fit into. Welded to together and back to the lathe to clean it up.

 

[Tools R Us]

As usual, when old stuff is taken apart, the column had issues. The upper bearing was very stiff, turn signal switch was a mess, needed a clean & lube job and had electrical connector issues. John successfully worked those.

The other issue was, no lower bearing. So used a hunk of acetal, cut away anything that didn't look like a bearing and press it in. Worked great, only has a thousandth or so of play and the column now spins free!

 

[Tools R Us]

We did a bunch of pick & pull searching for lower columns. Found one that we like from 2nd gen runners, pickups, this one came from a T100. Grabbed it along with some other spline sections that fit.
Cut the center part and used the same taper, index technique to extend it to the proper length. Worked great and is all stock Toyota parts.

 

[Tools R Us]

The spacing of the parts worked perfect! Good learning curve, we have two more of these conversions lined up after this one.

 

[Tools R Us]

Thanks for the Saturday help from AzTony!

Thought we were going to get lucky. One of the mini tie rods that I have, had a perfect end, hole for the steering stabilizer, correct thread, but the taper turned out to be wrong, hopes dashed! It works well enough to steer for now, but will have to make a new drag link that uses the needed ends. Then it comes back apart for box reseal and paint everything.

 

[Chuy]

Wow that is some awesome work nice job!

 

[azTony]

Jim's is a lucky guy to have this work done here by Kevin and company!

 

[Blues Dawg]

The thread makes it seem to be happening really quick...