My Jan 81 FJ40 Frame Off Resto Mod

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Splangy said:
The leaking manifold problem with headers is usually a result of the header flange being thinner than the intake flange. i would measure both with a pair of calipers. If they're in the ballpark, I would run it and use the OEM or Felpro gasket. If not, I would think about having them machined or going with the Remflex gasket.
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I checked the flange like you said and your spot on as usual.

The header flange is roughly 10 mm and the intake flange 8.5 mm. Or is it the other way around. Hmm.

Oh well I'll visit the machine shop this week.

Thanks Jeff!
 
It appears the header flange is thicker than the manifold flange. Also, the manifold has countersunk recess for bolt and washer, where the header does not. This countersunk area is part of the problem.

Also check out how the header on mating area is raised higher around each exhaust/intake. Wouldn't this cause trouble?

Seems like it would increase the thickness of the flange even more than it is already. Do I need to have this "boss" machined flat and have bolt side countersunk to match manifold?
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I would include that mating surface in the flange thickness measurement. You would probably have some pretty bad intake manifold vacuum leaks if you tried to install it like that. A Remflex gasket may be able to absorb the difference, but It would be a gamble. You may be able to stick half of a lock washer in the intake bolt recesses to make up the difference. Perhaps hold them in with a little JB Weld so they don't move on you while tightening. I'm not sure I would mill the mounting surface of that header. It looks like you may compromise the welds.
 
I took a thick washer and ground one side down with a bench grinder. Worked great. Although I don't think mine was as big a difference as yours.
 
Got some washers cut in half and set wit JB weld. I'm going to try this route first.

Now I've got a question for somebody.

I'm planning on re- installing Timing Cover and Crank Pulley. I'm ready to go but trying to figure out small brackets on backside of timing cover.

FSM shows longer bolts when using an oil cooler, but can't find any good pictures showing how this went. Can anyone snap some photos for me?
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KY Longhunter said:
Got some washers cut in half and set wit JB weld. I'm going to try this route first.

Now I've got a question for somebody.

I'm planning on re- installing Timing Cover and Crank Pulley. I'm ready to go but trying to figure out small brackets on backside of timing cover.

FSM shows longer bolts when using an oil cooler, but can't find any good pictures showing how this went. Can anyone snap some photos for me?
Click to expand...

That bracket in your hand is for the fuel line. It attaches to one of the timing cover bolts. I think there may be a little steel spacer (about 1/4" thick) that separates it from the front of the cover, too.
 
Splangy...thanks! your right I'm sure. Now that you mention it, I remember the spacer, but not sure where I put it.

But my original question was for the tube that goes from Water Pump to Oil Cooler. You sent me this picture which shows the part perfectly!

000_0143.jpg

BTW I made a pdf for my own benefit and thought I would post it here too.



View attachment Timing Cover Torque Guide .pdf
000_0143.jpg
 
Purchased the Copy-Cad plating system from Caswell Inc to replate some bolts. I figured I could buy new or blast and replate all my old bolts. Its worked pretty well (thanks Splangy!).

In the meantime I've gotten a little distracted. :rolleyes:

A buddy and I bought a 78 FJ40 as a wheeling rig.

I bought a 74 FST that Im still trying to figure what to do with.

and I bought a 62 FJ40 that popped up on Craigslist. Couldn't stop looking at it, so one day hopped in the truck pulling a buddies car dolly. Picked up the truck and started home when the trailer blew a tire in BFE. Had to leave the dolly and truck on side of parkway overnight until I could run 60 miles down the road and buy a new tire have it mounted then run back down the road to pick it up, bring it home then hide it in the tobacco barn until the :princess: finds out. :p

Now back to the 81.....
 
I can't find a part # for the copper crush washers for oil cooler. Can I just take this to parts store and find same size or does anyone know a part #?

Should I replace these on all bolts that hold oil cooler to block?

What would be length of 4 bolts that hold the oil filter to the block?

UPS man brought me some goodies...
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did you ever get the title sorted?
 
subzali said:
did you ever get the title sorted?
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nope. But I will register in another state like Maine where you dont need a title on older vehicles and then bring registration to Kentucky to get it titled in Kentucky.
 
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