Long Island 05/1981 FJ40 (2 Viewers)

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dr_dobro

SILVER Star
Joined
Sep 23, 2005
Threads
542
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2,112
Location
New York
This project wasn’t in my plans yet, but my son is too pumped with the idea of taking this 40 to High school Prom regardless of how she looks……. So, we put away my other 40 that was just a bad frame and empty axles housings under, no issues, it who’s laying for parts ?????? Off course I am ?????? And he wants to drive it ????? I just couldn’t say no, off course……

For now this will have a tight budget as I just want to make her safe and street legal. 40 has been sitting for almost two decades, 0w5 oil everywhere, turned by hand, change of oil and filter, dropped a nice carb with fresh fuel out of a small container: fired right away (couldn’t be happier) It only has 108,000 miles and things are just coming right off (crazy for the east coast)

Because it was sitting for so long, there was rust inside the fuel tank that was left with some fuel (stunk really bad) pulled it out for a spare replacement I had.

She’s getting entire coolant system, brakes and front axle overhaul (leaking bad) Tie rods, re curbed dizzy and carb fro Jim C (I had for sometime), fluids everywhere as usual land other small miscellaneous things.

We might work on her for the upcoming winter rather than continue with the crawler as this is much simpler, just not annoying body work !

Documenting for sure is great, two weekends into this, here she is along with @TheCarMaster40 working on his free time

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Good luck meeting your timeline— a planned event is usually when I get the most accomplished. No time to decide to expand the scope of work and keep fixing things!

Will be the coolest rig at the prom that’s for sure.
 
Between some nights and this weekend, we were able to change all brake lines, cleaning and prepping front axle knuckles with others.
Almost there, just need to temp re wire the rear of the truck as well as making my own replaceable fusible link. 40 will look weird (kind of like a sleeper) just Can’t wait to fire her again and adjust valves!

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We got her running last weekend !!!!! She runs really really good, checked valve clearances while running and they were not bad ! Really surprised for 108k miles…..
Buttoning her up this weekend and ready for an inspection sticker. Hopefully he can drive her to school Tuesday or Wednesday

More to come …

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Looking good Dean! Daniel, it looks like you doubled your garage space?!?
 
The 40 has already 250 under our possession, @TheCarMaster40 is really enjoying it, took it to his boces graduation ceremony to find out it poured while walking out of auditorium, he couldn’t care less. Glad wife and I took a separate car !

In other news
Couldn’t find an easy cheap fix for the 40 fusible link. 80 series is readily available with the same wire gauges….. ordered these parts and keeping a spare link at glove box department !
  • 90982-08264 Fusible Link
  • 82998-12470 Repair Wire
  • 90980-10982 Connector Housing
  • 82670-60040 Fusible Link junction block
Next thing is the Oil galley Plug. We found a small puddle of oil on the floor. Pretty annoying work, still pretty impressed for a car that hasn’t seen life in so long !

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The 40 has already 250 under our possession, @TheCarMaster40 is really enjoying it, took it to his boces graduation ceremony to find out it poured while walking out of auditorium, he couldn’t care less. Glad wife and I took a separate car !

In other news
Couldn’t find an easy cheap fix for the 40 fusible link. 80 series is readily available with the same wire gauges….. ordered these parts and keeping a spare link at glove box department !
  • 90982-08264 Fusible Link
  • 82998-12470 Repair Wire
  • 90980-10982 Connector Housing
  • 82670-60040 Fusible Link junction block
Next thing is the Oil galley Plug. We found a small puddle of oil on the floor. Pretty annoying work, still pretty impressed for a car that hasn’t seen life in so long !

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Great Job Daniel
 
Unfortunately discovered two horizontal fractures on the drivers side of the block. Small amount of antifreeze is oozing and evaporating before it can drop to the floor.
Pretty bummed out about it, most likely it sat too many years with small amount of antifreeze.
I ended up finding a complete drivetrain from a farmed purpose 1983 FJ60. Owner just saved the drivetrain as truck felt apart from rust. He claimed truck had low milage as it became a farm truck since the 90’s.

Took the 2F semi apart, so far looks great, Not tearing it all the way down) just cleaning it and re sealing for now. Along with that prepping a h55F swap with a 38mm split case. This winter will tear the 40 apart for a new due over !

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With the help of my kid , 40 is now fully disassembled. Chassis and body preparation for the next few months along with re-sealed 2F H55F and refurbished transfer case

Photo of the two horizontal hair line cracks at the drivers side of the block :(

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Can't find anyone to weld it up?
I know it's a bit of a pig, but it can be done.
Maybe worth drilling a stress relief hole at each end before they get any longer.
 
Can't find anyone to weld it up?
I know it's a bit of a pig, but it can be done.
Maybe worth drilling a stress relief hole at each end before they get any longer.
It could probably get done but that means tearing the engine apart and at that point do a rebuild for a weld repair. I opted for a cheaper version as I found a low milage donor. Going to run it the way it is for now
 
While waiting for some transfer case parts, we took most of the brackets off the frame and did quick sanding pass.
Alcan springs arrived, was super nervous that all of my measurements were on point, so far looks great in it, still planing to move the hanger brackets lower, in other words, one rivet down keeping the ride as low as possible (shackle end will sit horizontally at top of the extended frame/bumper)

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Blue tub was in really bad shape, PO had a body shop do this work and didn’t look bad from a top view. undercarriage was a disaster along with hidden rust.
Pulled my old tub (79) that’s rust free, with just a few bad trail dents and a front tree lean that twisted the cowl.
Matted a nearly perfect blue cowl to the 3/4 mustard tub.

Also, started fixing and extending rear frame rails for a custom welded bumper and to soon start the suspension work.

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Hoping this excitement doesn’t go away anytime soon, kid and I mocked the rear springs for a final depth frame extension dimension, setting a 45 degree shackle angle. Also getting ready to assemble the split case with new 4.1 gears, still waiting on a few miscellaneous Toyota parts….
Merry Christmas!

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Rear started to take shape, just a little too early to claim victory.
So far and after measuring a ton, the shackle hangers are perfectly aligned! Made a bracket out of 2x4 and welded the stock 38mm tube for the hanger at the bumper.
With this mockup going to start bracing the rear of the frame and finish the bumper.

Frame sits really high (26” to the bottom of frame). Going to cut 3/4” off the perches and hopefully, have it under 24” fully assembled with 40” tires.

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