Builds NLScooby's 1991 HDJ81 - a mild build (1 Viewer)

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Joined
May 29, 2009
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Location
North Carolina
After looking for a while, I found a nice looking, low mileage HDJ81 at an auto importer back in June and arranged a trade for a unique rat rod pick up that I owned (plus some cash). I spoke with the importer and this was one of the cleanest rigs he’d ever seen. Maintenance was all done…it was “perfect” and “ready for years of maintenance free ownership!”

Some details:
1991 HDJ81 VX
4.2 Liter 1HD-T
A442F Automatic transmission
Factory F & R electronic lockers and Center Diff lock
Full floating rear axle with rear disc brakes (non-ABS)
Center console refrigerator
No factory roof rack
Bone stock except for radio
127K KM

Below is an image from the importer’s website.
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The exciting day finally arrived along with the LC. The transporter driver hops out of the LC after unloading it and says (in broken English) “This no safe”…. He shakes the steering wheel and it is wobbling and totally loose. In fact it comes off in my hand as I pull it into the driveway! Ok - Interesting....
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As I finally get to inspect the vehicle further – I’m having mixed feelings. There is no rust on this thing anywhere and the overall condition is quite nice. But I also got to see all areas the creative camera work missed when taking 30+ photos for the ad. These weren’t deal breakers, but they would certainly eat into the accessory budget – and most would need to be addressed before we were at the point of “years of maintenance free ownership!”

Inner axles seals clearly blown on both sides:
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Cracked radiator “repaired” and leaking. Power steering reservoir and lines also leaking:

No sticker on the TB cover…so you have to assume the worst.

I contacted the seller and he apologized and offered to pay to have the front axle seals repaired at a shop using Toyota parts. He sent a check the next day. He also said he was sure the timing belt was done and upon closer inspection you could see the residue of where the sticker was…maybe it came off during the engine bay cleaning?


I was feeling pretty good….My first job was to tackle to tackle the inner axle seals. I changed it all: seals, races, bearings, etc…. It took me two days – but now I could do it in less than a single day with ease. Check out the diff oil pouring out of a place where it shouldn't be!
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Surprisingly, the nuts and bolts of this 25 year old rig were easy to remove –– not one rusted/broken fastener…hey, maybe this is the real thing! :)


Excited to start modifying the rig, I start ordering parts: a big box from @beno, custom sliders, OME lift kit, tires, radiator, etc… These numbers start adding up quickly!


For my hard work, I was rewarded with nice, clean axles and……a leaking injection pump! I hadn’t noticed it before, but the pump was leaking at the point where the distributive head meets the body. It had been leaking for some time. This is likely due to the seals aging and shrinking due to the non-sulfur fuel being introduced. This was not something I wanted to tackle myself so I trailered the whole thing to an injection pump specialist to have the work done:
 
So I decided to rent a U-Haul trailer and take it out to the shop...
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[**SIDE BAR** Now this is the point where sh!t hit the fan. I noticed on Mud that @SteveJackson posted a thread asking if anyone had purchased this vehicle….and there was the same image in his post that I shared above from the dealer. I thought Steve was jealous and secretly wanted to buy this rig for himself and was ready to offer me double what I paid for it. ;) Well, It turns out Steve had checked out this vehicle for someone else and discovered that the mileage in Japan was higher than it was stated and advertised for sale here!! Unless the importer drove it backwards from Japan (ala Ferris Bueller) and circled the earth 4 times, this truck had roughly 149K more KM on it than it was sold to me as. The worst part is the dealer was aware of it prior to selling it to me – and he sold it to me like that anyway…it even says so on my paperwork. So this is a 274K Km vehicle. (roughly 171K Miles) which isn't bad for a 25 year old rig, but it isn't what I bought and paid for...


So now I’m irate. I’m seeing red and am actually happy the dealer isn’t local for fear of what I might have done to him that could have landed me in jail for several years. I send the dealer a note and he responds back with “oh sorry about that…” and then he claims to have received the car like that from Japan and this isn’t the first time its happened! [odometer fraud] I’m considering legal action, but my wife was nervous because the importer is from and Eastern Block Country and she was worried about some sort of retaliation, etc…

We go through several rounds of negotiating and we agree at one point to simply “undo” the entire transaction. Upon further review and cooling down, I realize that this truck is actually a really nice rig – but it does have more miles than I paid for…..so we work out a deal and he agrees to write me a check for the difference in value.

A few days later the check finally arrives! Yay! :)……and after I let him know I received it and deposited it, he tells me to “hold on to it” for a few days….too late, it bounces! :( [check fraud]

Another phone call to discover there was fraud on his account and he offers to send me another check once its all cleared up.

A week later the new check arrives and I feel relieved. Yay! :) I deposit it and “boing”…..it bounces as well! :( Arg! By now my wife, who doesn’t share my passion for vehicles, is furious and worried…. He told me his account was closed earlier. [2nd count of check fraud]

I demand and finally receive (2 weeks later) a cashier’s check – and it was good :) Yay!….which was really good because all the bills were coming due for all the other stuff I had ordered! **END OF SIDEBAR**]


I get the HDJ81 back from the injection pump place with renewed energy in making it trail ready for a planned camping /4-wheeling trip with a group of friends.


First I needed to get it off-road just to see if the lockers work and get a base-line. Ok - I was just dying to get it in the dirt!.... The good part about an old worn out suspension is that it flexes without much complaint.....I think it flexes just by looking at it....
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I had picked up a set of new-car takeoff wheels and brand new BFG tires (see Classifieds section!!) – but then also found some FJ steelies I thought I’d try insteadl:

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I probably should have left them that primer grey color.....but more on that later....
 
So I'm on to the fun stuff finally!
White Knuckle sliders and an OME 2.5" lift: (yes, there are Jack stands under there - you just can't see them because they are magic jack stands. Actually the tires are blocking them....)
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Half-way there! I had to take it out and drive it with just the rear lifted and non-matching wheels.... (aha - see there's a jack stand right there.....)
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Lift done! Only thing now was to change out the steering stabilizer which should take just about 15 minutes.....right?
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Cant' really tell from this angle, cut there is a definite stink-bug rake to it that I'll try to gete rid of.....maybe some spacers or something. I'll let the rear end settle a little and go from there.
 
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WRONG!!! The steering stabilize was ironically the only thing to really give me any trouble on this Cruiser so far. See pic....
After messing around and making up new profanities, I did what any real man would do and I grabbed the sawsall.....:)
I felt better about myself but was still left removing the press-fit portion. I ended up drilling out the part until the wall was so thin that I could just tap it out.. So what I thought was going to take 15 minutes, took about 2 hours and 15 minutes.....
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Finally!
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My next job was to tackle all the following in one fell-swoop (and one weekend – right before the camping trip…what could go wrong?):

  • Replace radiator and radiator hoses, transmission cooler lines
  • Timing belt, spring, idler pulley, cam oil seal
  • Water pump, thermostat
  • Power steering reservoir and hoses
  • Valve cover gasket
  • All other belts
  • AC idler pulley
  • Fuel filter
  • Extended breather lines
  • Paint wheels and get MTs

So with all this important stuff to do, I naturally start by painting the wheels, right?

I really like the Toyota grey, but thought I’d go for the monochromatic U.N. look of body color painted wheels. I did my best to find Light Beige Cashmere paint – but had to settle for Cashmere Beige Metallic (or something like that)….which honestly, came out way too Gold for my taste….. But after having invested several hours of sanding, 3 coats of primer, 3 coats of paint and 3 coats of clear on all 5 wheels, I was DONE! I didn’t care what they looked like anymore….. So I ordered 5 BFG MT KM2s in 255/80/17 and had them mounted. Tall and skinny! That’s apparently what the ladies really dig these days….

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Then I had to get serious.....
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By the way, if you are looking for ideas for old condoms, you can use them to stop disconnected lines from leaking all over the garage!
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Wait.....those aren't mine! I was holding them for a friend...oh, that just sounds worse....nevermind.
Apparently these are tiny little water balloons that came in a party favor bag at one of my kid's b-day parties....(no, seriously.)

On to the tearing down..... (naturally I document everything with photos!)
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I just realized (when looking at this last shot) I probably could have used my condoms for the radiator hoses! (heh, heh)
 
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Phenomenal work so far.

The path is sometimes long and far and convoluted.

Wegmarken.
I appreciate your help and advice Beno. Phenomenal might be a strong word, but I'll take it! ;)
The fun stuff is just beginning.....
 
Looks like it will be a nice clean truck when you're done with it!

What was the deal with the steering wheel?!?
 
You are at a good point to check the valve adjustment. That was one repair that I made that seemed to make a decent hp gain. I had a few that were .001-.002 tight. I tried to make them all at middle to tighter portion of the spec.

Be sure to do the big end bearings BEBs/rod bearings and ACSD delete.

I would also highly rec. doing the big brake upgrade to the 93-97 rotors and calipers. Huge difference in braking power.
 
Nice progress so far. As Crab Shack mentioned, make sure to do the BEBs. Its not a bad job, the worst part is getting the oil pan off. One of those bent putty knives works pretty well for getting through the pan seal (its grey FIPG'd on).

Also a good recommendation on the big brake upgrade. Nice thing is its all bolt on for the front. The rear is a different story, the early HDJ81s use a weird disc size that's tough to find on this side of the pacific, and you have to change the backing plates to run the bigger NA rotors (also hard to find, or expensive). At least the rear calipers and pads are the same as 1993+ FZJ80.

These trucks are so solid, and once you get through the baseline maintenance you'll have a top notch runner there. Its good to hear that the seller made good by sending you the money. That could have gone way worse.

To anyone else thinking of bringing one over, I have used Providecars.com for both of my HDJ81 purchases, and they have been excellent to deal with and have excellent integrity. Their website has some good info to read through when considering bringing a vehicle over from Japan.
 
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Thanks for the advice gentlemen- I appreciate it! I will look into those things (BEBs, Brakes and valves.)
 
Looks like it will be a nice clean truck when you're done with it!

What was the deal with the steering wheel?!?
Thanks - I need to drop in some more photos - the engine compartment is starting to look nice!
I think the steering wheel was removed to have it recovered - but who knows!
 
Ha
The PO likely had custom wood grained steering wheel and decided to keep it.
Common sight in JP
 
Ha
The PO likely had custom wood grained steering wheel and decided to keep it.
Common sight in JP
That's true - good point!
 
So to continue on - as many know radiators for any early model 80 series are unobtanium from Toyota. @beno found one for me but it ended up being for a manual transmission - and thus didn't have the transmission oil cooler/warmer built in. @beno said he could source a genuine factory new part, but it'd come from Japan with a $1200 price tag! Whereas I do like keeping it original, I did some research and took a chance on a nice looking aluminum radiator. It was supposed to be a "drop in replacement" for the HDJ with 1HDT and an automatic transmission.

It's certainly shiny and really pretty!
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Unfortunately it required several modifications to make it a "drop in replacement"!

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Some stand-offs I had to make to get the side supports to line up. Then I had to cut the front wall brackets (tried slotting them at first) - but they were over 1/2" off from center to center! I also had to cut into the sides to get the fan shroud to mount without a huge gap between it and the radiator.
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I think I had this thing in and out of the engine bay at least 20 times!
The transmission line fittings that came with it were also straight out and the originals were at 90 degrees. I had new ones made for me out of aluminum as I didn't want to mix metals here and potentially cause corrosion.
 
So I got stuck at the Cam seal......somehow I didn't have it.
So I missed the deadline for the camping trip (with this rig).....but that was't going to stop me from going with my son. So I took our 200 series that is basically stock except for an ARB skid plate system and some RW wheels and tires. It performed flawlessly and was so smooth and confident off-road. I didn’t get any great action pictures, but I did manage to smack a tiny sign in a parking lot before we ever even got to the off-road part! ARG! Even with a backup camera AND parking sensors…..now that’s talent, folks! Actually, it’s worth noting that when you are on the Bluetooth phone, the backup camera doesn’t work and I don’t recall hearing the parking sensor at all! That’s my story and I’m sticking to it!
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Quite the ambitiousness for getting the 81 ready. It's always parts availability that slows you down on these builds. The good news is that you had a spare 200 laying around to get you where you needed to go. Great build keep updating the progress.
 
Quite the ambitiousness for getting the 81 ready. It's always parts availability that slows you down on these builds. The good news is that you had a spare 200 laying around to get you where you needed to go. Great build keep updating the progress.
Yes - I bit off more than I could chew and it turned out to be one silly seal that stopped me. And I wasn't quick enough to research and cross reference it to a seal that was available at my local Toyota dealership 3 miles away!

I always recommend people keep a spare 200 in the wings...you never know when you are going to need one! :)
 

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