Builds MRALD: 1997 FZJ80 Project (1 Viewer)

[SmokeSkiCA]

Hello iH8MUD. For the past year or so, I have watched, helped, and enjoyed my buddy's (iH8MUD handle: uscmas412) 1997 FZJ80 rig. He has upgraded his rig into an off-road hunting machine. So, this July, I pulled the trigger and purchased a rig of my own (from iH8MUD handle: McNally).

It is a 1997 FZJ80 with lockers, 122,600 miles, plenty of upgrades, and is well-maintained. I received the vehicle in early August and have done some basic maintenance on it thus far. My goal is to use this thread to track the progress of modifications, upgrades, maintenance, and, most-of-all overland adventures.

Here is my laundry list that will keep me busy and on a steady diet of ramen. Let me know what you guys think; always open to comments, suggestions, and recommendations.

PREVIOUS OWNER - REBUILDS
-Rebuilt Front Knuckles
-Rebuilt Front & Rear Brakes - Calipers, Pads, & Rotors
-Rebuilt Parking Brakes
-Repainted Factory Wheels
-Rebuilt Front & Rear Propeller Shaft U-Joints
-Rebuilt Rear Wheel Bearings
Rebuilt Steering Box

PREVIOUS OWNER - REPLACEMENTS
-OEM - Replaced All Fluids
-OEM - Replaced All Suspension Bushings
-OEM - Replaced O2 Sensors
-Replace Tie-Rod Ends
-Replace 90% of Brake Lines
-Replaced Fuel Tank & Fuel-Filler Neck
-Replaced Battery
-Replaced Dome Lights - LEDs

PREVIOUS OWNER - UPGRADES
-Upgraded Front & Rear Suspension - ARB 3” Lift
-Upgraded Tires - Cooper Discoverer S/T MAXX 255/85/16
-Upgraded Front Axle - Nitro Gear Chromoly
-Upgraded Fan Clutch - Toyota “Blue Hub" Fan Clutch
-CUSTOM - Upgraded High Clearance Front Winch Bumper - Custom 3/16” Steel
-CUSTOM - Upgraded Swing-Out Tire Carrier Rear Bumper w/Ladder - Custom 3/16” Steel
-CUSTOM - Installed 1.75" x .120 DOM Rock Sliders

PREVIOUS OWNER - MODIFICATIONS
-CUSTOM - Modified High Clearance Exhaust
-CUSTOM - Storage System
-CUSTOM - ARB 50 Fridge Slide
-Painted Two-Toned - MonstaLiner - Gray
-Rear Locker Skid Plate Guard
-Pin-7 CDL
-CDL Switch
-Installed Blue Sea Fuse Box
-Engo E9000s Winch w/ Synthetic Rope
-Viair 400H Compressor w/ Compressor Switch
-Aftermarket Head Unit
-Uniden CB Radio w/ FireStick 4’ Antenna
-Removed - ABS Brake System
-Removed - A/C System
-Removed - Rear Heater
-Removed - Fender Flares
-Removed - Factory Roof Rack

NEW PROJECTS
ENGINE, FUEL SYSTEM, & TOOLS

17-02 EXHAUST PIPE​

-Rebuild Exhaust​

-Remove Rust Scale​

-Sandblast Exhaust​

-Rebuild Exhaust​

TRANSMISSION & CHASSIS

37-01 PROPELLER SHAFT & UNIVERSAL JOINT​

-Remove Propeller Shafts​

-Disassemble Propeller Shaft​

-Sandblast Propeller Shafts & Components​

-Chassis Saver Propeller Shafts & Components​

-Rebuild Propeller Shaft​

-Reinstall Propeller Shafts​

41-01 REAR AXLE HOUSING & DIFFERENTIAL​

-Removed Rear Axle Housing Assembly - COMPLETE (2018-08)​

-Disassembled Rear Axle Housing Assembly - COMPLETE (2018-08)​

-Sandblasted Rear Axle Housing Assembly & Rear Axle Housing Cover Sub-Assembly - COMPLETE (2018-09)​

-Applied Rust Prevention to Rear Axle Housing Assembly & Rear Axle Housing Cover Sub-Assembly - POR15 - COMPLETE (2018-09)​

-Replaced Rear Axle Housing Side Collars - Toyota 42137-55010 - COMPLETE (2018-10)​

-Replaced Fill/Drain Plug & Gasket - Toyota 90341-18040 / Toyota 12157-10010 - COMPLETE (2018-10)​

41-02 REAR AXLE SHAFT & HUB​

-Remove Rear Axle Housing Assembly - COMPLETE (2018-08)​

-Disassemble Rear Axle Housing Assembly - COMPLETE (2018-08)​

-Replaced Oil Seals (For Rear Axle Shaft Outer) - Toyota 90311-62002 - COMPLETE (2018-09)​

-Rebuilt Hub & Bearing Assemblies - COMPLETE (2018-09) ​

-Replaced Tapered Roller Bearing (For Rear Axle Inner Bearing) - Toyota 90080-36064 - COMPLETE (2018-09)​

-Replaced Hub Bolts (For Rear Axle) - Toyota 90942-02052 - COMPLETE (2018-09)​

-Replaced Tapered Roller Bearing (For Rear Axle Outer Bearing) - Toyota 90080-36067 - COMPLETE (2018-09)​

-Replaced Rear Axle Bearing Lock Nuts - Toyota 42427-60021 - COMPLETE (2018-09)​

-Upgraded Rear Disc - DBA T3 - COMPLETE (2018-09)​

-Replaced Rear Axle Outer Shaft Flange Gaskets - Toyota 43422-60040 - COMPLETE (2018-09)​

-Upgraded Rear Axle Shaft - Nitro Chromoly Heavy Duty - COMPLETE (2018-09)​

41-03 DISC WHEEL & WHEEL CAP​

-Upgraded Wheels - 16” x 7.5” TRD Alloy Beadlock - Bronze - PURCHASED (2018-12)​

-Upgrade Tires - 37" BF Goodrich M/T​

43-01 FRONT AXLE HOUSING & DIFFERENTIAL​

-Sandblast Axle & Differential Housing - COMPLETE (2017-10)​

-Chassis Saver Axle & Differential Housing - COMPLETE (2017-10)​

-Replace Oil Seals - Toyota - COMPLETE (2017-10)​

-Replace Fill & Drain Plugs - Toyota - COMPLETE (2017-10)​

-Rebuild Front Differential Lock Actuator ​

43-02 FRONT DRIVE SHAFT​

-Clean & Inspect Axle Shaft - COMPLETE (2018-02)​

-Replace Shaft Snap Rig - Toyota - COMPLETE (2018-02)​

-Re-grease & re-install Axle Shaft - COMPLETE (2018-02)​

43-03 FRONT AXLE HUB​

-Sandblasted Axle Hub - COMPLETE (2017-10)​

-Chassis Saver Axle Hub - COMPLETE (2017-10) ​

-Sandblast Axle Flange - COMPLETE (2017-10)​

-Chassis Saver Axle Flange - COMPLETE (2017-10) ​

-Sandblast Axle Cap - COMPLETE (2017-10)​

-Chassis Saver Axle Cap - COMPLETE (2017-10) ​

-Upgraded Disc Rotors - DBA T3 - COMPLETE (2017-10)​

-Replace Bearings - Toyota - COMPLETE (2017-10)​

-Replace Hub Bolts - Toyota - COMPLETE (2017-10)​

-Replace Oil Seals - Toyota - COMPLETE (2017-10)​

-Replace Claw Washers - Toyota - COMPLETE (2017-10)​

-Replace Adjusting Lock Washers - Toyota - COMPLETE (2017-10)​

-Replace Gaskets - Toyota - COMPLETE (2017-10)​

-Replace Adjusting Nuts - Toyota - COMPLETE (2017-10)​

-Replace Shaft Snap Ring - Toyota - COMPLETE (2017-10)​

-Sandblast Knuckle Housing & Steering Arms - COMPLETE (2017-10) ​

-Chassis Saver Knuckle Housing & Steering Arms - COMPLETE (2017-10)​

-Rebuild Knuckles - COMPLETE (2018-08)​

-Replace Lug Nuts - Toyota - COMPLETE (2018-10) ​

45-01 STEERING COLUMN & SHAFT​

45-02 VANE PUMP & RESERVOIR (POWER STEERING PUMP)​

45-03 POWER STEERING TUBE​

45-04 STEERING WHEEL​

45-05 FRONT STEERING GEAR & LINK​

-Sandblast Steering Relay Rod - COMPLETE (2018-08)​

-Chassis Saver Steering Relay Rod - COMPLETE (2018-08)​

-Sandblast Steering Tie Rod - COMPLETE (2018-08)​

-Chassis Saver Steering Tie Rod - COMPLETE (2018-08)​

-Sandblast Steering Knuckle Arms - COMPLETE (2017-10)​

-Chassis Saver Steering Knuckle Arms - COMPLETE (2017-10)​

46-01 PARKING BRAKE & CABLE​

47-01 BRAKE PEDAL & BRACK​

47-02 BRAKE MASTER CYLINDER​

47-03 BRAKE BOOSTER & VACUUM TUBE​

47-05 FRONT DISC BRAKE CALIPER & DUST COVER​

-Remove Cylinder Assembly, Disc Brakes - IN-PROGRESS (2017-10)​

-Disassemble Cylinder Assembly, Disc Brakes ​

-Sandblast Cylinder Assembly, Disc Brakes ​

-Chassis Saver Cylinder Assembly, Disc Brakes​

-Rebuild Cylinder Assembly, Disc Brakes ​

-Reinstall Cylinder Assembly, Disc Brakes​

-Replaced Brake Pads - COMPLETE (2017-10)​

47-06 REAR BACKING PLATE & WHEEL CYLINDER​

47-07 REAR DISC BRAKE CALIPER & DUST COVER​

-Remove Cylinder Assembly, Disc Brakes - IN-PROGRESS (2017-10)​

-Disassemble Cylinder Assembly, Disc Brakes ​

-Sandblast Cylinder Assembly, Disc Brakes ​

-Chassis Saver Cylinder Assembly, Disc Brakes​

-Rebuild Cylinder Assembly, Disc Brakes ​

-Reinstall Cylinder Assembly, Disc Brakes​

-Replaced Brake Pads - COMPLETE (2017-10)​

47-08 BRAKE TUBE & CLAMP​

-Replace Brake Line Clips/Clamps - IN-PROGRESS (2018-12)​

48-02 FRONT AXLE ARM & STEERING KNUCKLE​

48-03 FRONT SPRING & SHOCK ABSORBER​

-Upgrade Front Suspension - Slee 6” Lift w/ Slee Shocks - COMPLETE (2018-08)​

48-04 REAR SPRING & SHOCK ABSORBER​

​

BODY & INTERIOR

51-51 FRAME​

-Removed Rust Scale - COMPLETED (2018-08)​

-Sandblasted Frame - COMPLETE (2018-09)​

-Power Washed Frame - COMPLETE (2018-09)​

-Applied Rust Prevention - COMPLETE (2018-09)​

ELECTRICS

86-01 RADIO & TAPE PLAYER​

-New Head Unit​

86-04 ANTENNA​

-Rebuild Antenna Assembly w/Holder​

87-12 HEATING & AIR CONDITIONING - HEATING UNIT & BLOWER​

-New Blower​

87-14 HEATING & AIR CONDITIONING - COOLER UNIT​

-New Cooler Unit​

87-15 HEATING & AIR CONDITIONING - CONTROL & AIR DUCT​

-New Ducting​

87-16 HEATING & AIR CONDITIONING - WATER PIPING​

-New Water Piping​

87-18 HEATING & AIR CONDITIONING - COOLER PIPING​

-New Cooling Pipes​

87-19 HEATING & AIR CONDITIONING - COMPRESSOR​

-New Compressor​

Upgrade Brake Lines - Slee Stainless Steel - IN-PROGRESS (2018-12)
Upgrade Front Propeller Shaft - PURCHASED (2018-10)
Upgrade Rear Suspension - Slee 6” Lift w/ Slee Shocks - COMPLETE (2018-10)
Upgrade Rear Axle - Nitro Chromoly Heavy Duty Rear Axle Shaft - COMPLETE (2018-10)
Upgrade Rotors - DBA T3 - COMPLETE (2018-10)
Upgrade Brake Lines - Slee Stainless Steel - IN-PROGRESS (2018-12)
Upgrade Air Intake - ARB Safari Snorkel - PURCHASED (2018-12)
Upgrade Hubs - Aisin Freewheel Hubs
Upgrade Head Unit - w/Apple CarPlay

 

[BILT4ME]

Welcome to 'Mud!!!


Post those plans that you want to spend all your cash on!

We all know what they are, but you need to affirm them in order to become a true addict!

 

[2fpower]

Put the wrench down and step away from the vehicle..... You need to plant a tree in your neighborhood.

 

[SmokeSkiCA]

Welcome to 'Mud!!!


Post those plans that you want to spend all your cash on!

We all know what they are, but you need to affirm them in order to become a true addict!

PREVIOUS OWNER - REBUILDS
Rebuilt Front Knuckles
Rebuilt Front & Rear Brakes - Calipers, Pads, & Rotors
Rebuilt Parking Brakes
Repainted Factory Wheels
Rebuilt Front & Rear Propeller Shaft U-Joints
Rebuilt Rear Wheel Bearings
Rebuilt Steering Box

PREVIOUS OWNER - REPLACEMENTS
OEM - Replaced All Fluids
OEM - Replaced All Suspension Bushings
OEM - Replaced O2 Sensors
Replace Tie-Rod Ends
Replace 90% of Brake Lines
Replaced Fuel Tank & Fuel-Filler Neck
Replaced Battery
Replaced Dome Lights - LEDs

PREVIOUS OWNER - UPGRADES
Upgraded Front & Rear Suspension - ARB 3” Lift
Upgraded Tires - Cooper Discoverer S/T MAXX 255/85/16
Upgraded Front Axle - Nitro Gear Chromoly
Upgraded Fan Clutch - Toyota “Blue Hub" Fan Clutch
CUSTOM - Upgraded High Clearance Front Winch Bumper - Custom 3/16” Steel
CUSTOM - Upgraded Swing-Out Tire Carrier Rear Bumper w/Ladder - Custom 3/16” Steel
CUSTOM - Installed 1.75" x .120 DOM Rock Sliders

PREVIOUS OWNER - MODIFICATIONS
CUSTOM - Modified High Clearance Exhaust
CUSTOM - Storage System
CUSTOM - ARB 50 Fridge Slide
Painted Two-Toned - MonstaLiner - Gray
Rear Locker Skid Plate Guard
Pin-7 CDL
CDL Switch
Installed Blue Sea Fuse Box
Engo E9000s Winch w/ Synthetic Rope
Viair 400H Compressor w/ Compressor Switch
Aftermarket Head Unit
Uniden CB Radio w/ FireStick 4’ Antenna
Removed - ABS Brake System
Removed - A/C System
Removed - Rear Heater
Removed - Fender Flares
Removed - Factory Roof Rack

NEW GOALS
FRONT AXLE HOUSING & DIFFERENTIAL
- Sandblast Axle & Differential Housing - COMPLETE (2017-10)
- Chassis Saver Axle & Differential Housing - COMPLETE (2017-10)
- Replace Oil Seals - Toyota - COMPLETE (2017-10)
- Replace Fill & Drain Plugs - Toyota - COMPLETE (2017-10)

FRONT DRIVE SHAFT
- Clean & Inspect Axle Shaft - COMPLETE (2018-02)
- Replace Shaft Snap Rig - Toyota - COMPLETE (2018-02)
- Re-grease & re-install Axle Shaft - COMPLETE (2018-02)

FRONT AXLE HUB
- Sandblast Axle Hub - COMPLETE (2017-10)
- Chassis Saver Axle Hub - COMPLETE (2017-10)
- Sandblast Axle Flange - COMPLETE (2017-10).
- Chassis Saver Axle Flange - COMPLETE (2017-10)
- Sandblast Axle Cap - COMPLETE (2017-10)
- Chassis Saver Axle Cap - COMPLETE (2017-10)
- Upgraded Disc Rotors - DBA T3 - COMPLETE (2017-10)
- Replace Bearings - Toyota - COMPLETE (2017-10)
- Replace Hub Bolts - Toyota - COMPLETE (2017-10)
- Replace Oil Seals - Toyota - COMPLETE (2017-10)
- Replace Claw Washers - Toyota - COMPLETE (2017-10)
- Replace Adjusting Lock Washers - Toyota - COMPLETE (2017-10)
- Replace Gaskets - Toyota - COMPLETE (2017-10)
- Replace Adjusting Nuts - Toyota - COMPLETE (2017-10)
- Replace Shaft Snap Ring - Toyota - COMPLETE (2017-10)

FRONT STEERING GEAR & LINK
- Sandblast Steering Relay Rod - COMPLETE (2018-08)
- Chassis Saver Steering Relay Rod - COMPLETE (2018-08)
- Sandblast Steering Tie Rod - COMPLETE (2018-08)
- Chassis Saver Steering Tie Rod - COMPLETE (2018-08)
- Sandblast Steering Knuckle Arms - COMPLETE (2017-10)
- Chassis Saver Steering Knuckle Arms - COMPLETE (2017-10)

REAR AXLE HOUSING & DIFFERENTIAL
- Sandblast Axle & Differential Housing - COMPLETE (2018-09)
- POR15 Axle & Differential Housing - COMPLETE (2018-09)
- Replace Oil Seals - Toyota - COMPLETE (2018-10)
- Replace Fill & Drain Plugs - Toyota - COMPLETE (2018-10)

REAR AXLE SHAFT & HUB
- Replaced Oil Seals - Toyota - COMPLETE (2018-09)
- Replaced Bearings - Toyota - COMPLETE (2018-09)
- Replaced Hub Bolts - Toyota - COMPLETE (2018-09)
- Replaced Lock Nuts - Toyota - COMPLETE (2018-09)
- Replaced Disc Brakes - DBA T3 - COMPLETE (2018-09)
- Replaced Gaskets - Toyota - COMPLETE (2018-09)
- Replaced Axle Shaft - Nitro Chromoly Heavy Duty - COMPLETE (2018-09)
- Standard Part Hardware - Toyota - COMPLETE (2018-09)

DISC WHEEL & WHEEL CAP
- Replace Lug Nuts - Toyota - COMPLETE (2018-10)
Replace Brake Line Clips/Clamps - IN-PROGRESS (2018-12)

Rebuild Front Differential Lock Actuator

Rebuild Knuckles - COMPLETE (2018-08)
Remove Rust Scale & Apply Rust Prevention - COMPLETE (2018-08)
Sandblast Knuckle Housing & Steering Arms - COMPLETE (2017-10)
Chassis Saver Knuckle Housing & Steering Arms - COMPLETE (2017-10)

Replace Brake Line Clips/Clamps - IN-PROGRESS (2018-08)

Rebuild Differential Lock Actuator

Rebuild Propeller Shafts
Remove Rust Scale & Apply Rust Prevention
Sandblast Propeller Shafts & Components
Chassis Saver Propeller Shafts & Components

Rebuild Brake Calipers - IN-PROGRESS (2017-10)
Sandblast Brake Caliper
Chassis Saver Brake Calipers
Replace Brake Pads - COMPLETE (2017-10)

Rebuild Exhaust
Remove Rust Scale
Sandblast Exhaust
Rebuild Exhaust

Rebuild Frame - COMPLETE (2018-09)
Remove Rust Scale & Apply Rust Prevention - COMPLETE (2018-09)
Power Wash Frame - COMPLETE (2018-09)
Sandblast Frame - COMPLETE (2018-09)

Rebuild A/C - Reinstall A/C
New Compressor
New Cooling Pipes
New Ducting
New Blower Unit

Rebuild Head Unit - Reinstall Head Unit & Troubleshoot Wires
New Head Unit
Rebuild AM/FM Antenna Motor & Switch

NEW GOALS - Rebuilds
Front Axle Housing & Differential
Upgrade Front Suspension - Slee 6” Lift w/ Slee Shocks - COMPLETE (2018-08)
Upgrade Front Rotos - DBA T3 - COMPLETE (2018-08)
Upgrade Brake Lines - Slee Stainless Steel - IN-PROGRESS (2018-12)
Upgrade Front Propeller Shaft - PURCHASED (2018-10)

Upgrade Rear Suspension - Slee 6” Lift w/ Slee Shocks - COMPLETE (2018-10)
Upgrade Rear Axle - Nitro Chromoly Heavy Duty Rear Axle Shaft - COMPLETE (2018-10)
Upgrade Rotors - DBA T3 - COMPLETE (2018-10)
Upgrade Brake Lines - Slee Stainless Steel - IN-PROGRESS (2018-12)

Upgrade Wheels - 16” x 7.5” TRD Alloy Beadlock - Bronze - PURCHASED (2018-12)
Upgrade Air Intake - ARB Safari Snorkel - PURCHASED (2018-12)
Upgrade Tires - 37”
Upgrade Hubs - Aisin Freewheel Hubs
Upgrade Head Unit - w/Apple CarPlay


Here's my laundry list that will keep me busy and on a steady diet of ramen. Let me know whatcha guys think, always open to comments, suggestions, and recommendations.

 

[shocktower]

First , and get the thing out of Flo Rida , enjoy the hours of fun and the ramin meals

 

[BILT4ME]

It's the Pin-7 mod, not the 7-pin mod..........(Some day you'll understand)

Nice list!

 

[2fpower]

First , and get the thing out of Flo Rida , enjoy the hours of fun and the ramin meals

Hopefully you heeded his advice, and are out of florida. Additionally, hopefully you did not take my advice and plant a tree as it will likely become a projectile soon.

 

[SmokeSkiCA]

Hello again, iH8MUD. So, it has been a while and time for an update to the build page. Long story short, it's moving slow.

Still working through the laundry list of goals with the help of my buddy (iH8MUD handle: uscmas412). Anyways, enjoy the pictures and let me know whatcha guys think. I'm always open to comments, suggestions, and recommendations.

Giving The New Project LC A Once Over... Lots Of Rust

Tore Out The Front Axle

Time To Rebuild

Knuckles - Before

Knuckles - After

 

[SmokeSkiCA]

More pictures.

Old Front Passenger Side Rotor Destroyed

Front Hubs - Before

Front Hubs - After

 

[SmokeSkiCA]

More Pictures.

Time To Paint - Front Axle Painted w/ Chassis Saver Aluminum

Looking Better - Front Axle Painted w/ Chassis Saver Black

Front Hubs - Painted w/ Chassis Saver Black

Knuckles - Painted w/ Chassis Saver Black

Front Hubs Complete w/ New DBA T3 Front Rotors & Hardware

 

[gummycarbs]

I'm surprised at the amount of material eaten away on the top side of that axle. Obviously you need more leaks rust inhibiting emission points.

 

[SmokeSkiCA]

Back on iH8MUD and progress is finally picking up. A weekend project has turned into a year's project; but something worth doing is worth doing right. Stripped her to the frame (body on), sandblasted her, and painted her with Chassis Saver Aluminum and Black. Rebuilt the front brakes, knuckles, suspension, and steering components. Rear frame, brakes, axle, and suspension in-progress.

Still working through the laundry list of goals with the help of my buddy (iH8MUD handle: uscmas412). Anyways, enjoy the pictures and let me know whatcha guys think. I'm always open to questions, comments, suggestions, and recommendations. Thanks.

New Front Brake Calipers

New Front Slee Shocks

Front Driver Side Frame w/Aluminum Chassis Saver

Front Passenger Side Frame w/Aluminum Chassis Saver

Front Suspension/Axle/Brake Rotors Complete

 

[SmokeSkiCA]

More Pictures.

Before - Front Suspension/Axle/Brake Components - View From The Front Of The Vehicle

After - New Slee Front Lift w/Suspension & Steering Components/ Rebuilt Front Axle/ New Front DBA T3 Brake Components - View From The Front Of The Vehicle

Before - Front Suspension/Axle/Brake Components - View From The Passenger Side Rear Of The Vehicle

After - New Slee Front Lift w/Suspension & Steering Components/ Rebuilt Front Axle/ New Front DBA T3 Brake Components - View From The Passenger Side Rear Of The Vehicle