Mike's 1978 FJ40 Build

[78fj40mg]

I just purchased this 54mm socket from Cores West in Seattle, it should be here tomorrow.

 

[TheHardWay]

If you can't wait, tap an old screwdriver counterclockwise against the nut - if the lock ring has been straightened so it's not keeping the nut from moving, should loosen easily and you can unscrew it, pull off the lock ring and unscrew the inner locknut.

 

[78fj40mg]

Could not wait for the socket to arrive so I lightly tapped it and the nut came off, I will still need the socket for the passenger side and also to reinstall the nuts.

Removed the inner nut and bearing

and removed the disc brake

next I unbolted the steering arm to loosen the upper pin

then removed the spindle

 

[78fj40mg]

Now I have quite an accumulation of parts

next pulled the axle

To be continued...

 

[Jdc1]

Great timing, my front axle will probably be my next big project.

 

[78fj40mg]

Removed bearings

and the bearing races, I used a piece of rebar and tapped them with a hammer

couple of blows with the hammer and they popped right off

I also removed the 'BAD" seal that was leaking oil in the knuckles

clean up is next

 

[Solace in Solitude]

Great documentation Mike!!

 

[1Fine40]

Your work is great! I've already been through much of what you are doing now, and it is such gunky fun! For that inner axle seal, try getting the ones from Marlin Crawler. The "eco-seal" is superb, and I have had zero leaks from it in 5 + years of use/abuse. FWIW, I really like Them
Keep up the great work and especially the pix!

Cheers!

 

[78fj40mg]

Some goodies arrived yesterday!

5mm socket and a few extras that came with it

Steering knuckles rebuild kit

 

[Solace in Solitude]

How come you haven't installed this stuff yet, Mike?

 

[78fj40mg]

I called in sick today.

 

[78fj40mg]

I've been doing research on steering knuckle centering tools including the Toyota SST which is expensive and hard to come by. I found another centering tool solution that appears to be easy enough to make and should be relatively inexpensive. Courtesy of Pirate4x4.Com

Here's the tool

Specs for tool can be made out of any material

This is how the bushing fits in the axle housing with a dummy shaft to center the knuckle

Once the knuckle has been centered after you've added the appropriate number of shims to obtain the desired 13Lbs preload then install the real axle and you are done.

Installation and centering procedure here Pirate4x4.Com

 

[FletchFFletch]

Mike, great work! THANK YOU for taking the time to document this. Your efforts will help many tackle a job like this that they otherwise might not have. Not to mention, just adding to the mud knowledge base! Also, I like how you make sure to put the tool that was used for a particular step in the picture.

 

[fj401978]

You're an awesome documenter! Thanks for all the details, Mike...sure going to come in handy!!

 

[DSB345]

Great detail and Info on tools etc.

 

[78fj40mg]

Thank you guys I appreciate the accolades!
More to come soon...still ironing out all the details and lots of cleaning.

 

[78fj40mg]

Steering Knuckle Centering Tool Ideas and Discussion Thread

 

[78fj40mg]

Here's my attempt to make a centering tool:


I decided to attempt to make one of these centering tools made out of wood. I'm not sure of all the dynamics of this as yet and how it will actually work or not work, but I wanted to run this by y'all for some constructive comments, suggestions and improvements or to just trash it, what ever you guys think. So here's what I did:

The original idea from Pirate4x4.Com was this:

Here's my wood contraption on sketch form as a single solid shaft and bushing combined following all the dimensions as indicated

I started with a piece of stock wood

I turned the dowel and bushing combo with very tight tolerances

It fit like a glove, (very tight glove), in the shaft housing I'm happy with how it turned out but the question is will it work?

 

[Solace in Solitude]

You are very creative Mike!! Nice Jet tools too!!

I'm not mechanically gifted, but I think, if your tolerances are tight, it will probably work well... For a limited number of iterations, being its wood.

But, for the number of times you are likely to use it, use it carefully and it will probably serve you well.

Of course, given I know very little about the science behind the knuckles tolerances... I could be wrong...

 

[DSB345]

Very creative!