Mike's 1978 FJ40 Build

[78fj40mg]

Today I started the passenger side knuckle disassembly what a horrifying condition it was in. When I cracked it open it was like black gold, Texas tea, I felt that I struck oil as the crude came pouring out of dark cavity where grease used to once live and lubricate the birf. Now comes the most unpleasant part of having to clean the crude mess.

Here's the good part of the goo free flowing down into pan, it smelled like money to me but was only a momentary dream of black gold then reality set in Wow now I have to clean up this effluent? Someone needs to invent a knuckle diaper.

Neatly contained in my tray just like a TV dinner

Have y'all had enough pics yet?

This is what happens when a good oil seal goes BAD! It transforms grease into crud. My knuckles will never be the same!

Stay tuned for the cleanup, the Valdez clean up team is about to commence tidying things up...

 

[78fj40mg]

Mike,
Not trying to hijack but I was wondering if you or others might be able to steer me right. I bought Warn rebuild kit #7309. My gaskets are black and It doesn't seem to have the small inside O ring, and has a large O ring that I haven't figured out where it will go. I haven't completely disassembled them, but my initial thought it that it is wrong. What kit did you buy? Pic attached of my style hub and the kit.

I used a new O ring, have a huge supply of O rings, but did not purchase a rebuild kit. Give me couple of hours and I'll take some pics of the O ring placement for you.

 

[emac]

Don't trouble yourself. I have a large o ring set and can probably figure something out. I was just curious about the kit . At least I got t be gaskets. Mine didn't have any...just a bunch of sealant that was everywhere.

 

[78fj40mg]

@emac My knuckle rebuild kit came with all the gaskets but no O ring. The purpose of the O ring is to seal the locking mechanism dial from water and debris from entering and destroying the grease and gears, the ring gets pushed in and it's a real tight fit. I'll post pics later, no trouble at all, anything to help a fellow mudder!

 

[emac]

Thanks, I guess when I open my knuckle rebuild kit I will discover that i have another set of gaskets. Oh well, if all I waste on this build is $29 I will feel real lucky.

 

[78fj40mg]

@emac here's the O rings I used

 

[emac]

Thanks, I have the exact kit! One in Metric one SAE (blue).

Several years ago I got all bent out of shape searching for some matching fasteners in my garage. In my fit of rage, I bought a stack of metal drawers, and filled them with all different sizes of grade 8 hardware. Also bought stuff like the O ring, circlip, etc kits. I probably dropped 500-700 on everything. Some of the best money I have ever spent...right up there with a lift.

 

[GA Architect]

Today I started the passenger side knuckle disassembly what a horrifying condition it was in. When I cracked it open it was like black gold, Texas tea, I felt that I struck oil as the crude came pouring out of dark cavity where grease used to once live and lubricate the birf. Now comes the most unpleasant part of having to clean the crude mess.

Here's the good part of the goo free flowing down into pan, it smelled like money to me but was only a momentary dream of black gold then reality set in Wow now I have to clean up this effluent? Someone needs to invent a knuckle diaper.

Neatly contained in my tray just like a TV dinner

Have y'all had enough pics yet?

This is what happens when a good oil seal goes BAD! It transforms grease into crud. My knuckles will never be the same!

Stay tuned for the cleanup, the Valdez clean up team is about to commence tidying things up...

Just plain NASTY!

Good thing you took and posted this, because in a few days these photos will be a long ago remembrance of images that will soon be forgotten..........I expect to see it looking like the photo below very soon:

Nice work, my friend!

 

[FletchFFletch]

Today I started the passenger side knuckle disassembly what a horrifying condition it was in. When I cracked it open it was like black gold, Texas tea, I felt that I struck oil as the crude came pouring out of dark cavity where grease used to once live and lubricate the birf. Now comes the most unpleasant part of having to clean the crude mess.

Here's the good part of the goo free flowing down into pan, it smelled like money to me but was only a momentary dream of black gold then reality set in Wow now I have to clean up this effluent? Someone needs to invent a knuckle diaper.

Neatly contained in my tray just like a TV dinner

Have y'all had enough pics yet?

This is what happens when a good oil seal goes BAD! It transforms grease into crud. My knuckles will never be the same!

Stay tuned for the cleanup, the Valdez clean up team is about to commence tidying things up...

It's a dirty job, but someone has to do it! You the man, Mike!

Whew! I can smell it from here!

 

[78fj40mg]

You are right Kris someone has to do it, so here it is the parts are getting cleaned but who's going to clean the parts washer?

 

[TheHardWay]

Not me.

 

[rkymtnflyfisher]

A parts washer would've made my knuckle rebuild a heck of a lot easier! I cleaned all my stuff in an oil drain pan with a degreaser spray! Man that sucked.........

 

[78fj40mg]

@emac here's the O ring and locking hub assembly:

Location of O ring

Location of second O ring

Locking dial pushed into hub body

Washer and snap ring

Greased

Locking mechanism installed a bit tricky to reassemble

Completed assembly

Painted with oil paint

 

[FletchFFletch]

I like the nicks and scars on the hub -- gives it character!

 

[78fj40mg]

I like the nicks and scars on the hub -- gives it character!

Thanks Kris! I'll have to beat up the driver's side for some added character.

 

[emac]

Thanks for the pics. I had some time today to get into mine. The second O ring in your picture is actually a U ring and has square edges. At least in mine it does. Mine is broken.

I called WARN and got a really nice guy on the phone, he searched all his documents and finally found a box that had some of these U rings. According to him the hubs were made by WARN for Toyota and they had unique parts. At least that was his thought, as to why the kit didn't have the right seals. The ones in the rebuild kit are too big and are round. He gave me the part number and I can post it when I get them in the mail and make certain they are correct.

Does that make any sense? I can post some pictures tomorrow, I just don't want to jack your thread with my issues. Since I am in SC, and it is going to be raining for the next few days, I will have plenty of shop time.

 

[emac]

Is that the HF parts washer? $49 one? Just picked one up last week, you can't beat the price. Heck, don't clean it, just get a new one!

 

[78fj40mg]

Thanks for the pics. I had some time today to get into mine. The second O ring in your picture is actually a U ring and has square edges. At least in mine it does. Mine is broken.

I called WARN and got a really nice guy on the phone, he searched all his documents and finally found a box that had some of these U rings. According to him the hubs were made by WARN for Toyota and they had unique parts. At least that was his thought, as to why the kit didn't have the right seals. The ones in the rebuild kit are too big and are round. He gave me the part number and I can post it when I get them in the mail and make certain they are correct.

Does that make any sense? I can post some pictures tomorrow, I just don't want to jack your thread with my issues. Since I am in SC, and it is going to be raining for the next few days, I will have plenty of shop time.

You are correct my second -O- is a -U- ring I just didn't know what to call it. Interesting that these WARN hubs were specifically manufactured for Toyota, learn something new every day. I'd love to see some of your pics.

 

[78fj40mg]

Is that the HF parts washer? $49 one? Just picked one up last week, you can't beat the price. Heck, don't clean it, just get a new one!

Yeah that's an HF parts washer got it several years ago for $99. I hear you about not cleaning it but I still have the used de-greaser fluid to deal with.

 

[emac]

Took some pics for you. First two pictures are of some of the parts I have been refinishing. Everything is getting disassembled, cleaned and painted inside and out. I have been trying to use stock finishes whenever possible. I know it doesn't look like much, but those parts were mostly red when I started. I spent an hour tonight getting the windshield washer motor running. It was rusted solid, but the Kroil oil saved it.

The last picture is of all the body parts waiting for the sand blaster. It hasn't rained much at all the last two months......until I got the body ready to clean. My sandblaster guy has a mobile unit and only works on the weekends. It has rained the last three weekends. He does soda, walnut shell, and sand. The frame is at the powder coater and should be ready next week.

I dropped the engine off to be built yesterday. It is going to be built all stock.No smog, and a trolhole carb and dizzy. I am curious to see what he says about the condition of the motor. Fingers crossed., as I never heard it run.

I would like to have the chassis built with the suspension and driveline by Thanksgiving.

You got the bigger HF parts washer. The one you see in the background is the $49 one. Years ago, I flipped the switch on a parts washer and the switch shorted, sparked, and the parts cleaner caught on fire. Burnt all the hair off of my arms, and about caught the shop on fire. No more flammable cleaners for me.