ntsaint's FJ40 search and build

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Maybe the later 40's did but both of the 40's I have had (74 and 78) had dealer installed lock out hubs.

On a "period correct" build the warrens are probably more appropriate.
 
Back at it. Hope to get both sides down to the knuckle today.

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Pulled the front calipers, drained all the fluid. Gonna replace the calipers and the rotors with new. I could refurb but honestly the cost to do it isn't worth the time it will take.

Got it stripped all the way down to the inner knuckle seal, both of which had apparently failed. Gear oil everywhere inside there.

Knuckle rebuild kit and all new wheel bearings on the way from Cruiser Outfitters. All parts getting a bath in the parts washer this week.

Next weekend hope to reassemble. Cap it off with new rotors and calipers, front will be done. Then it's on to the rear.

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Just a FYI, I stock Terrain Tamer knuckle kits now.
 
Also, if the rear is not leaking, don't screw with the axle seals. Just drain the diff and axle, clean up the brakes and button it up. I have almost never seen that rear axle seal fail unless it was replaced.
 
Also, if the rear is not leaking, don't screw with the axle seals. Just drain the diff and axle, clean up the brakes and button it up. I have almost never seen that rear axle seal fail unless it was replaced.

Yeah I completely disassembled and redid the rear the first time through. New bearings and seals. Not leaking a drop. Long as it looks fine back there just gonna do the rotors and calipers.

By the way, front Knuckle bearings on passenger side were so bad the raceways had grooves in them...
 
Pulled the rear tires and brake gear today. Gonna stop there, everything else looks fine.

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Also dropped the rear driveshaft in preparation for the Ebrake rehab.

While I was under there I noticed that there is a pretty serious leak at the transfer case. Only a couple drops on the ground after a couple weeks, BUT the entire bottom half of the xfer case was coated in gear oil.

Looks to be leaking from the plate that's bolted into the side of the xfer case, and from where the rear driveshaft/ebrake drum bolt onto the xfer case. Also may be leaking where it mates to the transmission.

What do I need to do here? Really don't want to drop the whole thing...

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Sometimes the seal between the two goes out and the transmission will pump oil into T case.

There is a kit that is basically a return line to the transmission.

Could be your leak. Drain tranny see how much comes out
 
Before you drain it, stick your pinky in the fill hole on both and see if one is more full than the other.
Or if fluid comes pouring out one of the fill holes when you open it, you know the seal between the two is bad.
 
Clean it up real good and see where it leaks from. It might be easiest to keep some cardboard under the truck.

The speedo housing looks like it may be contributing, that's something you can reseal without tearing the whole thing down. If these are set up like the split case, you could also replace the output seals without pulling it all apart.

If it leaks between the tranny & transfer (but doesn't sound like it if it wasn't overfull), I'm not sure I would go to the trouble to fixing it.
 
Clean it up real good and see where it leaks from. It might be easiest to keep some cardboard under the truck.

The speedo housing looks like it may be contributing, that's something you can reseal without tearing the whole thing down. If these are set up like the split case, you could also replace the output seals without pulling it all apart.

If it leaks between the tranny & transfer (but doesn't sound like it if it wasn't overfull), I'm not sure I would go to the trouble to fixing it.


That's my current plan. I ordered several gaskets for it, gonna get all the way to where the speedo housing bolts on, and work my way back with new seals. I've got to get in there anyway to fix the ebrake. If that doesn't do it...it's just gonna have to drip. :)
 
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