I have been bad about keeping the updates flowing to this thread, but I have HUGE news. Yesterday she passed her Texas Vehicle Safety Inspection! It has been an amazing, challenging, (though not as expensive as I thought) ride. For anyone embarking on this "hobby" I have this advice.
Don't get overwhelmed. These forums are amazing for their knowledge, but also for the moral support they provide. Others have been right where you are, sitting in a steaming hot garage, with a disassembled "thing" trying to solve the "why doesn't this work?" question.
- Get organized, figure out the goal for the next month (or two).
- Make a list of what you need to get there. In my case the goal was passing the inspection. The list came from the Texas Vehicle Code.
- Work one problem at a time while you order the parts for the next problem. Having a steady supply of parts rolling in kept me productive on the weekends.
In getting to this momentous point, I have:
Taking her out for a drive was thrilling. Once I get my plates and tag Monday she's off to get new tires.
- Replaced the fuel tank and all fuel lines
- Replaced the rear brakes and brake lines
- Replaced the master cylinder
- Re-soldered and fixed the backup switch and lights
- Rewired the rear blinkers
- Replaced and rewired the rear marker lights
- Rewired the front turn signals
- Repaired the horns (makes me smile every time I honk and hear the lovely "chord" it plays.)
- Manufactured horn button springs
- Rebuilt the replacement Rochester carb
- Rebuild the rear lift struts
- Restored the license plate frame
I plan to write up or add to existing threads some of the additional stuff I have learned along the way, like testing circuits. Seems like a lot of folks struggle with the electrical component of working on an FJ40. I find it easy if you follow the FSM. My favorite "makes me smile" moment happened recently while troubleshooting the engine temperature sender. I think of this as a 1960s engineer sending me a message from the past.
Congratulations! Very cool, so nice to hear!
I would be very interested in your writeup on how to test circuits! I am an absolute noob and completely tear apart my fj40. So consider me signed up for this guide
Anyways enjoy your ride!