Just picked up a 1976 FJ40 to bring back from the dead

[charliemeyer007]

Relay? Head light, horn, ??/ Looks like a wire is broken off. Wiring diagram look for a unit with 1 Green w/ white or yellow stripe 2 Green and maybe 3 wire

 

[pb4ugo]

It looks like the horn relay. It mounts using one of the apron bolts

 

[Pighead]

It looks like the horn relay.

My first thought too.

 

[franklin40]

yes horn relay

 

[igotta40]

Horn relay. It attaches to the fender.

 

[TheHardWay]

HORN RELAY !!!!!!!

Got it?

 

[TEQ4RPRO]

Horn was my guess. Headlight should have 5 wires at least on most cars. New to the 40 world. Welcome and nice start.

 

[knuckle47]

Looks like a horn relay?

EDIT: just responded to this ..when I hit enter, the new posts thing pops up at the same time and there are loads of replies…what a great group

 

[accidentaltexan]

So, I’m gathering that no one is really sure, but this might be the horn relay?

I wonder if other car groups have as much willingness to help? Thanks for the quick replies. You guys are great!

 

[RodrigzCrzr]

Yes that is your horn relay.

 

[anothernz45]

Looks like a horn relay - bolts down low on RH firewall

 

[kenjera]

Next question. What is this? I can't find any markings. It's floating loose, but it looks to me like the bracket should bolt in close to where the coil should be (will be, when it finally gets here...)
View attachment 3790809View attachment 3790810

A start relay by the looks of it...

 

[accidentaltexan]

Things have…progressed a bit. A little bit of “scope creep.” Somehow I slid into a frame-off. Not a complete, every-bolt-original-every-part-OEM restoration, but a “do it right to last a long time so I don’t regret NOT doing when I had the chance” renewal.

Engine bay is empty now. Aprons and fenders off with the expected number of broken bolts (about 6). Wiring harness out. Firewall completely stripped of parts. Dash almost cleared…just have to pull the wiper motor and sub-harness. I dropped the engine block and head at the machine shop yesterday, as well as the flywheel, which needs resurfacing. Opening the top of the transmission to inspect today.

Just about ready to pull the body off.

My dad, and my brother, (whose car interests are much broader than mine), have often had two or three car projects going at once, sometimes for years. After sharing pictures of my progress, my brother had an insight that made me laugh long and loud: “Our family has a god-given gift for disassembly. It’s the reassembly that seems to be our Achilles.”

I am determined to beat that legacy with this 40.

 

[charliemeyer007]

Disassembly when done correctly makes reassembly a piece of cake, when done wrong it creates scrap metal. I always love folks that dyke off wires right next to the plug - couldn't be bothered to take 2 seconds to up-plug the connection or leave a tail so you could read the color code.

A good reason tools should only be sold to folks that can pass a simple test. Some folks could ruin an anvil with a rubber mallet.

 

[Coolerman]

If you only knew the number of harnesses I have worked on where, to remove the harness from the truck, they literally cut it into pieces, then sent it to me for repair.

Another criteria all FJ40 owners should be required to meet before owning one? Having patience. These trucks may look simple but can test the patience of even the most diehard fan...

 

[accidentaltexan]

Disassembly when done correctly makes reassembly a piece of cake, when done wrong it creates scrap metal.

@charliemeyer007, you couldn't be more right. Luckily, that's a mistake I've only made a dozen or so times. Much more disciplined as I age.

Another criteria all FJ40 owners should be required to meet before owning one? Having patience.

@Coolerman, SPOT ON. This is my third FJ40. First one since having kids (so fourteen years!). I find that my daughters have trained me to be waaaay more patient. It also helps that this project isn't my daily driver. My first two FJs were also my only transports, so there was a sense of desperation every time something went wrong.

And speaking of things going wrong, this weekend I opened up the transmission to inspect, and discovered a whole new sub- project:

I've never done a transmission before. I have the FSM, a transmission rebuild kit, various bearing pullers/installers and a good attitude. Anything else I need or should be on the lookout for?

 

[1911]

I've never done a transmission before. I have the FSM, a transmission rebuild kit, various bearing pullers/installers and a good attitude. Anything else I need or should be on the lookout for?

A 20-ton shop (floor) press, if you’re going to be replacing any gears.