Mike's 1978 FJ40 Build (1 Viewer)

[78fj40mg]

Well done, Mike

Thanks Dave!
I'm hoping the right side will go much quicker now that I've learned all the ins and outs of knuckle rebuilding, a very big Thanks goes to MUDDER'S and their How-To threads which I followed and learned from.

 

[TheHardWay]

I guess you've been there done that?

Except for all that extra cleanin' and paintin'. Yours will be showroom ready. Mine's gonna be carport ready.

 

[78fj40mg]

Except for all that extra cleanin' and paintin'. Yours will be showroom ready. Mine's gonna be carport ready.

Yours was my inspiration to do this rebuild because initially I had cold feet.

 

[firestopper]

Nice job!
On the inner snap ring, I found that a correct sized hose clamp (just on the edge) not too tight but enough to compress the snap ring works really well for installation of shaft.

 

[fj401978]

Mike, you have done an awesome job...I am SOOO jealous! I will be going over your posts and pics when I tackle mine, thank you for the extra trouble of your excellent documenting!
Your rebuild is a great inspiration!

Skip

 

[78fj40mg]

Nice job!
On the inner snap ring, I found that a correct sized hose clamp (just on the edge) not too tight but enough to compress the snap ring works really well for installation of shaft.

Thanks for the great idea! I'll try your method when I do the passenger knuckle rebuild.

 

[78fj40mg]

Mike, you have done an awesome job...I am SOOO jealous! I will be going over your posts and pics when I tackle mine, thank you for the extra trouble of your excellent documenting!
Your rebuild is a great inspiration! Skip

Hey thanks Skip! I appreciate your enthusiasm and kind words.
I would have taken more pics but unfortunately it was a greasy job and wasn't able to pick up the iPhone at will for each step of the rebuild to snap additional pics. When I tackled this rebuild my goal was to do one side at a time so I would have one intact knuckle for reference during reassembly and sure enough I used the reference on more than one occasion.

When you are ready to rebuild yours let me know as I'll be happy to help you and discuss any issues by phone or email.

 

[78fj40mg]

Installed the locking hub housing and gasket, temporarily used a 10mm bolt to pull/push the axle to properly seat the snap ring in place.

Removed 10mm bolt and installed the locking hub mechanism with anew star gasket.
Also used oil based red paint to accentuate the instructional lettering.

 

[78fj40mg]

The brake caliper dust boots are toast, they are not tight around the pistons and prone to water/debris infiltration, will have to remove the boots and determine the extent of damage and/or if any corrosion is present. If there's any corrosion present I will either rebuild the calipers or just replace them. Any recommendations?

The dust boots are really fubar!!

 

[jgeoffr]

Remanufactured calipers from Toyota are available for about $50 per side.

-Geoff

 

[78fj40mg]

Remanufactured calipers from Toyota are available for about $50 per side.

-Geoff

Thanks Geoff, I didn't know that refurbished Toyota calipers were available. I'll check with @beno tomorrow.

 

[FletchFFletch]

Installed the locking hub housing and gasket, temporarily used a 10mm bolt to pull/push the axle to properly seat the snap ring in place.

Removed 10mm bolt and installed the locking hub mechanism with anew star gasket.
Also used oil based red paint to accentuate the instructional lettering.

Red is a sharp touch, Mike! You're going all out! Awesome!

 

[emac]

I really like the look of the red paint. I painted mine last night, but stuck with black. I didn't even think about red. Nice touch.

Is the black retainer/washer under the mounting nut (in your picture) still available? I have looked at several kits that come with washers and lock washers, but I haven't seen any of those retainers. Like yours, several of my tabs are broken. Thanks for all your pictures. I am several steps behind you, and learning a lot.

 

[78fj40mg]

I really like the look of the red paint. I painted mine last night, but stuck with black. I didn't even think about red. Nice touch.

Is the black retainer/washer under the mounting nut (in your picture) still available? I have looked at several kits that come with washers and lock washers, but I haven't seen any of those retainers. Like yours, several of my tabs are broken. Thanks for all your pictures. I am several steps behind you, and learning a lot.

@emac I'm not sure if they still carry those washers, I cleaned and painted mine to look new again.

How about some pics of what you're doing?

 

[78fj40mg]

Red is a sharp touch, Mike! You're going all out! Awesome!

Thanks Kris! It's the little touches that make a difference. I'm sure you'll be doing the same soon.

 

[78fj40mg]

Picked up two reman Toyota calipers today from NAPA at a great price and they look good and no painting required.

Caliper installed on driver's side

 

[Racer65]

How are your brake tubes that screw into the calipers? When I did this job, the calipers were super easy, but both brake tubes had small cracks at the flared end and started leaking.

 

[78fj40mg]

How are your brake tubes that screw into the calipers? When I did this job, the calipers were super easy, but both brake tubes had small cracks at the flared end and started leaking.

I'll have to look at them tomorrow as I didn't pay much attention to them today.

 

[78fj40mg]

This little tool bag arrived yesterday, it is used and a bit dirty but I'll clean it and make mine.

 

[emac]

@emac I'm not sure if they still carry those washers, I cleaned and painted mine to look new again.

How about some pics of what you're doing?

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.