New FJ40 tear down and some questions

[ellesar04]

Okay, a few new questions.

1. I'm down to the frame with the motor still on. I've removed the transmission and the clutch fork and bearing assembly. How the heck do I get the clutch assembly out of here? I'm trying to get the motor off and on a motor stand but need to get the housing off first. This Haynes book I have is no use whatsoever.

2. I removed the thermostat housing, but when trying to get the upper and lower units apart, guess what? Both bolts broke. Options?

3. Once I get the motor put back together, is there a way to test everything to see if it will crank up without having to install the whole wiring kit first?

4. On this 1970, the drain plug is HUGE. Could someone tell me the size socket I need for this? Hate to buy a whole extra large set for just the one.

Also, I'm working on this in Fulshear, just west of Houston. If you ever wanna come help a goofy kid out, let me know.

 

[Coolerman]

1. I'm down to the frame with the motor still on. I've removed the transmission and the clutch fork and bearing assembly. How the heck do I get the clutch assembly out of here? I'm trying to get the motor off and on a motor stand but need to get the housing off first. This Haynes book I have is no use whatsoever.

There are four bolts holding the bell housing on, but you first have to get the six flywheel bolts out as two of the bell housing bolts are under the flywheel!

2. I removed the thermostat housing, but when trying to get the upper and lower units apart, guess what? Both bolts broke. Options?

Get a new housing. Post in the wanted section here on MUD. IF you have more time than money they can be drilled out...

3. Once I get the motor put back together, is there a way to test everything to see if it will crank up without having to install the whole wiring kit first?

You only need a hot wire to the plus side of the coil and the idle solenoid and a + battery connection to the starter and a - battery connection to the block. Use a screwdriver to short the ignition terminal to the battery terminal on the starter solenoid to start the engine.

4. On this 1970, the drain plug is HUGE. Could someone tell me the size socket I need for this? Hate to buy a whole extra large set for just the one.

a quick search revealed the size is: 24mm or a 15/16" will fit. Worse case use an adjustable wrench.

 

[ellesar04]

How do I separate the clutch from the flywheel? I've removed the fork and bearing but that's as far as I can see. Like I said, the damn thing is full of oil so It's hard to see much of anything.

edit: nevermind, I got it. WD-40 is better than any degreaser out there. Although I did see why it would slip out of 3rd. There was absolutely no surface left on the friction disc. It was a mirror finish. Anybody need a pressure plate for a 1970 FJ40? I have a brand new one in the box I'm going to put on with the new friction disc.

Now I know I'm supposed to mark the flywheel according to the incredibly vague Haynes manual. What am I marking it for? What do I mark it with? Do I just piss on it for grins to mark my territory to claim "You're my bitch, flywheel!"? Also, how the heck do I keep the flywheel from spinning when I try to loosen those six bolts? i've got my cheater bar and all that good stuff, I think I may just be too powerful.

 

[ellesar04]

It looks like the surface on my flywheel is awfully messed up too. I'm hoping they can machine it, if not, gonna have to try and find a new one.

P.S. That lovely bumper hitch you see in the picture at the very top,complete with lights, is now FOR SALE. You know you want it. You can land planes on it. These FJ40's are made from the old Japanese fleet, and now you can return the steel to its original purpose: landing warplanes.

 

[secondattempt]

Anyone know who want to get rid of on of these cover plates? The cone shaped one?