Builds My 1993 FZJ80 Build (1 Viewer)

[xetura]

I completely forgot that I replaced the Neutral Safety Switch with a brand new one (from Impex). That's what got me into working on the rig again. What a pain in the ass! My giant hands really hated this job and the crappy thing is, the connector is corroded. So while it's installed and working (truck starts), I'll be cutting the old connectors off and using a new Deutsch style connector. My gear indicators aren't working after installing the new one and I'm not able to stay in low gear, either. It worked fine before replacing it, so hopefully I can figure that out.

 

[Trapper50cal]

I feel you on the neutral safety switch...I had one go out while was 30 miles into the backcountry elk hunting. Thank god I was at like 11,000 feet so my cell phone worked (good line of sight) and my cruiser buddy had to drive half the day to come help me out...serious boonies. It wouldn't let me put it back into park, IIRC.

 

[xetura]

I feel you on the neutral safety switch...I had one go out while was 30 miles into the backcountry elk hunting. Thank god I was at like 11,000 feet so my cell phone worked (good line of sight) and my cruiser buddy had to drive half the day to come help me out...serious boonies. It wouldn't let me put it back into park, IIRC.

View attachment 3341527

That's a really crappy place for it to go out! Glad you were able to get it going and didn't get stuck. I followed the manual and made sure the line was vertical to the truck, so i'm not sure if it still needs to be adjusted and that's why my low gear isn't working 100%? I'm assuming the gear indicators not working is just the corroded connector, though. Did you have to adjust the new one further to get it to go into park again?

 

[Trapper50cal]

...Did you have to adjust the new one further to get it to go into park again?

No, but I had the OEM unit and no corrosion. I was able to start it in neutral with a jump, then it went back into park.

 

[xetura]

I was able to get the rear 95% covered in sound deadening. Still have the rear left quarter panel left, so hopefully I can finish that tonight. Unfortunately Noico is no longer available (which is what I was using), so I had to go with a different brand (Siless). The siless stuff is better (120 mil vs 80 mil) and the closed cell foam has a foil backing for heat, but it looks mismatched in the photos. Oh well, it'll all be covered by carpet anyway.

 

[xetura]

I also whipped up a design and printed it for the rear speaker hole that's no longer used. This one houses 29mm usb and 12v accessories that you can find on Amazon. Any design can be made that fits within the center. The only thing I'm waiting on to finalize this is the threaded heat inserts. Then I need to get my new printer assembled so I can print it in ABS since PLA will warp in the heat.

 

[xetura]

Didn't get much done yesterday, but I have to tonight because we're going camping tomorrow. It'll be my 2.5 year old son's first camping experience, so we decided to try it out on my brother's 5 acre property. If things go south, it's easy to abandon ship haha (unlike being 2.5 hours away from home up on the mountain). I think he'll do fine and he's super excited.

First thing was to clean up these rusty and crusty seat mounts and tie-downs. Unfortunately, my bench grinder died when I was only 5 bolts in, but at least I got the mounts done. I took apart the grinder and found out it was the stupid switch that melted. Works fine when I just connect the wires. Good ol Harbor Freight lol. At least it was just the switch, though. Easy fix.

Old and crusty.

Much better.

Not pictured, but I got the rear carpet back in and ran into an issue where the sound deadening was too thick where the center seats bolt in, so I had to cut away a spot for those. It was a huge pain in the ass since this sound deadening is really sticky, but I guess that's a good thing. Got one seat bolted in, but I have to wash the other one before I get it back it. Then onto the rear carpet for a nice deep cleaning.

 

[xetura]

Got the cruiser put back together for our short campout. It was my son's first camping and roasted marshmallow experience. Needless to say, it was a great success. He already wants to go again. Our dog was in heaven as well. Slow cooked a cross-rib roast and had a nice dinner for my mom's birthday. A great weekend for sure.

 

[xetura]

I decided to start rewiring the neutral safety switch, so I pulled the starter (ended up being a lot easier than I expected). It looks like the previous owner broke the plastic housing for one of the connectors on the starter. I searched everywhere on here for a replacement part, but I only found the connector that goes on the wire. Not the one on the starter itself. Anyone have any ideas on where to get it? Or am I screwed? The starter works fine, but I couldn't find any manufacturer data on it.

I couldn't find any other info on the starter. Just this number. You can see the masterful zip-tie specialty on this one.

Yikes.

 

[xetura]

With no answers yet on the starter connector, I started tackling the Neutral Safety Switch (NSS) wiring. I originally wanted to repair the pins on the OEM connector, but they were $7/each and the OEM connector was obviously failing to do its job. After de-pinning and labeling it tonight, I definitely made the right decision... this thing is SCREWED.

Before the claustrophobic chaos.

It looked repairable from the outside, but I'd quickly realize that's not the case.

Yikes. It just fell apart.

Not as bad, but still nasty.

lol

 

[xetura]

This one wasn't crusty, just BURNT.

All de-pinned and labeled.

The housing just fell apart on the inside on a few of the connectors. It was really brittle.

I'm done for tonight, but tomorrow I'll document which wires go where and all the wiring details. I'll be using a Deutsch style connector.

 

[xetura]

I went ahead and snipped off all the old connectors, stripped the wires and crimped on the deutsch pins. Then put it all together. I REALLY like these connectors. Especially since I can disassemble it without cutting any wires or pins and put them in a different size housing if I want.

This was just a test to see if everything worked as expected. I'll be heat-shrinking the wires before I finalize anything.

Ohhhh, what is this? It's working? I'm way too excited about this haha.

 

[xetura]

Great success!

 

[xetura]

Original wiring:

NSS side:
1.) Yellow
2.) Black
3.) Red
4.) Green
5.) Tan
6.) Peach
7.)
8.) Blue
9.) White

Harness Side:
1.)
2.) Yellow
3.) Red
4.) Red with blue stripe
5.) Black with orange stripe
6.) Brown
7.)
8.) Red with black stripe
9.) Green

I don't know if the numbers are exactly what Toyota labeled them originally, I just matched the wiring from nss to the harness.

I used 8 pin connectors, so I skipped the 7th pin since neither used it.

 

[xetura]

Thanks to @Malleus and @Kernal I found the broken solenoid connector part number: 76-82576 I ordered it from Maniac Electric Motors for $5 w/free shipping. It'll be here early next week.

While I wait for that to get here before I put my starter back in, I decided to do a bunch of random stuff.

I pulled the cowl to see if it needed cleaning. Nope, looks great..

Got it all vaccuumed out, but haven't 'cleaned' it quite yet. I have a leaf or something in my heater fan I need to get out. I thought I could get to it from here, but I guess not.

Then I had some parts come in to secure the rear trim plate (5 grommets and screws). It's never been tied down as long as I've owned the truck, so this seemingly small thing was really satisfying for me.

Before.

After. Much better and solid! Willow approves.

 

[xetura]

I also started cooking a brisket this morning at 8am. 5 hours in right now, about 4-5 left to go.

Threw in the trimmings for the second half of the cook.

I also got some upgraded washer nozzles for the front and got them installed last night. I'll get installed pics tonight. I need to figure out why the rear nozzle isn't working, though. It used to work.

 

[Malleus]

ASR sells the impossible to find shorty Toyota branded (Vessel?) screwdriver (singly or in the complete set); indispensible for the cowl panel screws, with the hood in place.

 

[Kernal]

Good work

 

[xetura]

The brisket turned out amazing. It was my first one, so now I want to get a bigger one (of course).

For the NSS harness, I decided to use fabric harness tape instead of heatshrink. There is absolutely no room in that workspace and it wouldn't be possible to use heatshrink effectively unless I unhook the harness further up and take it out. I didn't feel like doing that, so I used this stuff. Worked great.

 

[xetura]

The starter part came earlier than expected. Unfortunately, it doesn't work with the plug on my rig. I remember seeing a thread somewhere about the ends being different on certain models, so I'll have to find a new wire end so it'll work with this.

I haven't been successful at taking the existing plug out of the starter housing yet. I think I just need to get a bigger pair of pliers.