New Engine for a 1975 FJ40 Named "Sandy"

[cstav86]

Regarding the radiator, it can easily move forward a bit. Here's from my writeup doing this same activity last year:
To accommodate the clutch fan and larger water pump I moved the radiator support holes 3/4" forward. Basically as far as they would go to where the radiator frame bumps up against the front frame crossmember. I replaced the canvas looking isolator with a neoprene koozie I cut up. Interestingly the radiator support rods didnt require any modifications and everything looks square. Could be because I added new rubber bushings there too. I thought for sure with the 3/4" move the rods would pull the top of the radiator forward, but it didn't.

 

[Chungas Revenge]

Just being safe, I have too much invested to screw up now.

It only gets worse. I think I set my dizzy at least 6 times “just to make sure”..

 

[MatthewMcD]

Regarding the radiator, it can easily move forward a bit. Here's from my writeup doing this same activity last year:
To accommodate the clutch fan and larger water pump I moved the radiator support holes 3/4" forward. Basically as far as they would go to where the radiator frame bumps up against the front frame crossmember. I replaced the canvas looking isolator with a neoprene koozie I cut up. Interestingly the radiator support rods didnt require any modifications and everything looks square. Could be because I added new rubber bushings there too. I thought for sure with the 3/4" move the rods would pull the top of the radiator forward, but it didn't.

Good to know. I'll save that activity for when I drain the DI water and refill with the good stuff...also have to reinstall the heater. (Though, in Texas it was 80F today!) 1/2" would do it.

 

[MatthewMcD]

Found a different fan from Cruiser Outfitters that should sit further back on the clutch and give me a bit more breathing room. Can't say enough about how patient they are with questions @cruiseroutfit.

I removed the throw-out bearing and replaced it with a fresh one. I should get an extra 5 MPH based on how stuck the old bearing was. This leads me to a question. I have impact sockets up to about 40mm. (Plus a 54 for the wheel bearing.)

So, 90% of the time, do you use your big sockets on big nuts or do you use them for installing and removing seals and bearings?

Poll above.

 

[charliemeyer007]

What ever works. When the clutch is in (throw out bearing working) you are getting 0 mpg j/k

 

[cruiseroutfit]

Found a different fan from Cruiser Outfitters that should sit further back on the clutch and give me a bit more breathing room. Can't say enough about how patient they are with questions @cruiseroutfit.

I removed the throw-out bearing and replaced it with a fresh one. I should get an extra 5 MPH based on how stuck the old bearing was. This leads me to a question. I have impact sockets up to about 40mm. (Plus a 54 for the wheel bearing.)

So, 90% of the time, do you use your big sockets on big nuts or do you use them for installing and removing seals and bearings?

Poll above.

Right on, glad to hear that. They have actually been pressuring me to build out a fan blade spreadsheet with blade #, OD, width, mounting offset and mounting pattern. I've done that with water pumps and fan clutches but blades are a day long task. One day!

 

[MatthewMcD]

Right on, glad to hear that. They have actually been pressuring me to build out a fan blade spreadsheet with blade #, OD, width, mounting offset and mounting pattern. I've done that with water pumps and fan clutches but blades are a day long task. One day!

Only a day? Don't you have like 30 fans?

 

[cruiseroutfit]

Only a day? Don't you have like 30 fans?

At least 30 blade part numbers here, 5+ of which are still in the "Kurt, will you please add these to the retail system" aisle upstairs , meaning we have them in stock I've not had a chance to add them to our retails system. Those are mostly non-US diesel stuff. I think I could rock through measurements and dimensions on all of them pretty quickly honestly.

 

[MatthewMcD]

Transmission day. We’re stuck at about 2” to go. Any advice to get us over the line?

 

[charliemeyer007]

I always take out and put in the engine/tranny/transfer in one piece. Getting the input shaft and clutch splines ... lined up in the rig is a PIA for me compared to doing outside where I have room to move and see what is going on. Your alignment pins should help a lot. There is lots of weight pivoting on the pins so push up at the back of the transfer as you slide forward should help.

 

[77mustard40]

Matt walk it on the rest of the way with hardware, making sure to go bolt to bolt to keep everything even. Are you close enough to get your final bolts in place?

 

[Pighead]

We’re stuck at about 2” to go.

That always happens. Wiggle and jiggle while applying forward pressure. I have used ratchet straps to keep tension on it while doing the wiggling/jiggling

 

[MatthewMcD]

I always take out and put in the engine/tranny/transfer in one piece. Getting the input shaft and clutch splines ... lined up in the rig is a PIA for me compared to doing outside where I have room to move and see what is going on. Your alignment pins should help a lot. There is lots of weight pivoting on the pins so push up at the back of the transfer as you slide forward should help.

Thanks. We repositioned the jack to the rear and wiggled. Tightened the guide bolts and spun the flywheel. Tighten a bit more and BOOM. It jumped forward 1/2”

It’s all in!

 

[Grayscale]

I was going to say that if you shift it to fourth, and in gear on the transfer case. Twist the parking brake drum. Get the splines to line up.

Engine crank would do the same thing, relatively.

 

[RevISK]

Crazily you texted me while I was struggling with the same thing. Wiggle wiggle jiggle push twist…

 

[MatthewMcD]

We finished reattaching the drive train and buttoned up a few other items. Tomorrow we'll start fresh and try and start it.

 

[MatthewMcD]

AND...she's running! Once I sorted out the distributor orientation (and depth) with the ever present help of @bparker we did the initial break-in run and let it rest a bit. I rechecked the valve clearances and bumped the idle speed a little. We reinstalled the driver's seat and drove it out of the shop for some fresh air.

Fired it up again and did a second break-in period. Drank a beer with my buddy and held the throttle while he replaced the front bumper. The only part left on the shop floor is the skid plate. I'll reinstall that next weekend after an oil change.

The clutch is "crisp". It'll take a little getting used to.

 

[RevISK]

Awesome. Looking forward to seeing it in person.

 

[77mustard40]

Congrats Matt, a well-built fresh 2F should last a lifetime!

 

[MatthewMcD]

Awesome. Looking forward to seeing it in person.

Looking forward to showing it off. I have some cable and hose routing to deal with and the radiator to deal with. Once I have that I feel like I can take a breath and just enjoy driving it.

Congrats Matt, a well-built fresh 2F should last a lifetime!

That's my hope! It feels great to have this behind me. It was stressful doing it remotely. My friends are saints for allowing me the time and space to get it done right. Can't wait to get it back home.