Mike's 1978 FJ40 Build

[78fj40mg]

Wow, what great work and great documentation. I am looking at a reseal project as well but ...... can't get sucked into the vortex.... no because it wouldn't be fun and interesting.... just want to drive it some more first....

By the way are you planning the Trans/TC hose connection now that everything is new and tight?

Thanks for kind words, it's a labor of love. I'm on the fence with the trans/TC hose connection, I've driven these babies for many years and never had an issue without the hose, as long as you check oil levels periodically you shouldn't have a catastrophic anomaly. If there's any empirical data that documents these failures then I may consider the hose.

 

[fj401978]

Great write up and pics...you do good work! I rebuilt my front heater as well, it's amazing how cruddy they get! I flushed the core it seems forever before it started running clear. Very nice '40 you have there

Skip

 

[78fj40mg]

Great write up and pics...you do good work! I rebuilt my front heater as well, it's amazing how cruddy they get! I flushed the core it seems forever before it started running clear. Very nice '40 you have there

Skip

Thanks Skip I appreciate the kind words!
You are absolutely correct these heaters are crud traps, hope that I don't have to clean another one any time soon.

 

[78fj40mg]

I pulled the blower unit to find another mess as usual the sealing foam had disintegrated and the unit was basically filthy, below are the pics depicting the restoration process.

All the dead foam removed ready for washing and disinfecting

 

[78fj40mg]

After a thorough cleaning installed the sealing foam

All sealed and reconnected, now I can sleep better knowing that I will be breathing cleaner but still a little polluted air

 

[MyCruiserisaHogBeast]

Wow, just ran across this thread, NICE WORK! I've got a 79 and I've been dreaming of having the time and garage space to do this. I've been afraid to even start because of the "might as well do this because I'm in there" thing. A blown up t case had it MIA for almost a year after I had my daughter.

My engine looks pretty good from the top, but as you work your way down with a flash light by the time you get to the bottom you're a sad panda...
I've been toying around with doing the oil pan at least. I think that's where a lot of the carnage is coming from. How bad was the oil pan by itself?

 

[78fj40mg]

Wow, just ran across this thread, NICE WORK! I've got a 79 and I've been dreaming of having the time and garage space to do this. I've been afraid to even start because of the "might as well do this because I'm in there" thing. A blown up t case had it MIA for almost a year after I had my daughter.

My engine looks pretty good from the top, but as you work your way down with a flash light by the time you get to the bottom you're a sad panda...
I've been toying around with doing the oil pan at least. I think that's where a lot of the carnage is coming from. How bad was the oil pan by itself?

Thanks!
The oil pan was not bad at all, the worst part was cleaning many years of leaking oil that turned into gunk other than that it was straight forward the way I re-installed mine. However, while you are in there doing the oil pan it would be the proper time to do the rear main seal and the front main seal if they are leaking oil.

 

[78fj40mg]

Continued today with the blower installation and all associated ductwork

Installed to fresh air damper cable

All ductwork installed

 

[fj401978]

What are you cleaning your plastic with...I cleaned my 'squirrel cage' fan, but it didn't come out white like yours is! Looks great!

 

[78fj40mg]

I also installed the gear shifter and boots

 

[78fj40mg]

I used 1/2 inch foam pipe insulation to cover the gear shifter and transfer case shifter

Brand new TC shifter knob

 

[78fj40mg]

What are you cleaning your plastic with...I cleaned my 'squirrel cage' fan, but it didn't come out white like yours is! Looks great!

Hey Skip, I purchased this stuff called purple power from Autozone very nasty stuff you have to wear gloves and eye protection but it does clean well.

 

[fj401978]

Great, thank you! I'll have to get some. I've seen it, just have never tried it.

 

[78fj40mg]

This afternoon I was kinda bored and the shop was a bit nippy so decided to pull all the knobs and get them cleaned and painted in the warmth of my home, here are the results in the various painting steps.

Cleaned knobs before painting

Knobs painted kinda rough looking

So I used some fine sand paper to clean off the excess paint

Final results

Not perfect but acceptable, I'm sure there are better ways to achieve similar or better results but this was my way of doing it with a Sharpie white and red oil based paint pens from Micheal's crafts shop.

 

[78fj40mg]

Great, thank you! I'll have to get some. I've seen it, just have never tried it.

Skip be careful with this stuff as it's very toxic. Spray the cleaner and let sit for about an hour then rinse with water.

 

[78fj40mg]

Installed painted knobs

 

[78fj40mg]

Added additional protection for the winch

Before

After

 

[ColonelMustardFJ40]

I also used sound deadening material on the floors as you did. Mid summer I was cleaning out my FJ40 and found that the deadening material held water and would eventually cause new rust. Took it out.

 

[78fj40mg]

I also used sound deadening material on the floors as you did. Mid summer I was cleaning out my FJ40 and found that the deadening material held water and would eventually cause new rust. Took it out.

Thanks for the heads up! I will do the same and remove it.
Thanks again!

 

[78fj40mg]

I finally got all fluids in and ready for the road.

I also adjusted the mining and RPM and she's running like new.