Late model FJ40 door installation instructions

[hindsight]

Alright, I am sure that many of you can identify with this scenario...I took my doors apart more than a year ago, now I forgot exactly how they go back together. The manual is not much help either.

I put the following instructions together for the sake of saving your sanity when it comes down to remembering the sequence of assembly.

First of all....find a nice sturdy surface to hang the doors on. If they are on your truck, it will probably be all the easier.

The door latch is next, I remembered how hard the stainless bolts were to get out so I made sure to apply some anti-sieze to the threads.

Next in goes the cylinder door lock, I could not find the stock rubber gaskets so I applied a little clear silicone instead.

Should look like this installed

Next...in with the door handle

Inside view

Bolt it up like this...what the picture does not show is that the armature should be swung upwards and bolted to the door

Clean out the old window channel to install the new rubber guides

I lubed the guide with Silicone seal to aid in lubricating the rubber guide.

A brisk push with a very long screwdriver

Now in place

 

[hindsight]

Preparing the next guide although a couple of steps will pass before it goes in

Now for the window mechanism

Bolts go here

And here

Now to install the felt wipers

Easier if the mounting surface is facing you...these suck to put in BTW

Done

Good time for lube

 

[hindsight]

Roll the window mechanism all the way down



Tip the window in...don't worry it will wiggle through the new felt wipers.

It takes a little finaggling but eventually you will get the window upright and bolted in.

Hint make sure the leading edge is in the new rubber channel

Roll the window all the way up and install the new channel on the opposite side.



Install the outer handle and you are pretty much done










http://i61.photobucket.com/albums/h...0 Project/FJ40 Door installation/100_0221.jpg

 

[hindsight]

Reserved for door skin and upper channel

Doc

 

[krzyabncanuck]

Just took 2 apart today for a redo. Along with the whole truck though.

 

[antFJ]

dude. nice thread

 

[Christian]

This should definetely be added to faq!

 

[TCSTARK]

Well done Sir! This is exactly what I needed to get the job done right.

Sent from my iPhone using IH8MUD

 

[EgyptOffroad]

Thank you Hindsight, great useful thread.
I got 2 new omp Window handles, and 2 Taiwanese (after-market 40 series) exterior door handles. I cant find new cylinder door locks though.

 

[gabe4jlc]

Window install

Great job on the write-up.

Curious what you used for the upper felts....

Thanks,

Gabe

 

[Interpol]

Thank you so much for this thread.

 

[bikersmurf]

WD 40 is designed to displace water. Over time it gels up. Id use white grease or other lube.


Good writeup though.

 

[FJsnoozer]

Wonderful thread.

On my doors, when I lock them and close the door, it unlocks. I cannot lock the doors with the key, but if they are locked from the inside I can unlock them with the key. Does this make sense to anyone? Do I have the Cam in incorrectly, or is this likely a Key issue?

 

[1911]

On my doors, when I lock them and close the door, it unlocks.

That's the way they're supposed to work; you have to hold the outside handle up as you close them to stay locked. Supposed to help you make sure you want them locked, and not accidentally lock your keys in the truck.

I cannot lock the doors with the key, but if they are locked from the inside I can unlock them with the key. Does this make sense to anyone? Do I have the Cam in incorrectly, or is this likely a Key issue?

Don't know, but something is not right.

 

[PandaTelf]

Thanks, very useful thread. Saved me a lot of head scratching.

 

[myquestoyota]

Thank you Hindsight, great useful thread.
I got 2 new omp Window handles, and 2 Taiwanese (after-market 40 series) exterior door handles. I cant find new cylinder door locks though.

http://www.cruisercorps.com/door-lock-set-1-1975-1984.html

I've had better luck with the OEM Toyota door handles.

 

[PandaTelf]

What part am I missing between the lock and the arm? Searched the old parts and can't find a part to connect the two...

Any help appreciated.

 

[mumphra]

I couldn't tell you as i don't own doors... but that is a damn fine write up with some damn fine doors if i ever saw them.

 

[PandaTelf]

Argh, checked every resource I can find, I'm convinced I am not missing a piece. Tried bending them (true Aussie way of making things work) to meet each other but then they didn't meet up.

Are my locks wrong? Are there longer ones available?

 

[antFJ]

doesn't that rod with the green clip go in it? put the clip in the hole first and then the rod