Nut & Bolt Frame-Off 1978 FJ40 Restoration

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Yeah...Warren hubs, Warren wench, Ranchero lift...it'll be an awesome FJ jeep.

Glad to see the 200 finally earning avatar status.
 
Tmost original was drive flanges. Most didn't get locking hubs until the dealer swapped them out
 
Huge percentage of '78 in the US had Warn.
 
Rear axle is almost done.

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Installed bellhousing, and moving onto clutch installation. Used new hardware, and also used red locktite and FIPG on the heads. Thanks for the suggestion, @offr0adlim0 .

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New clutch fork boot and inspection cover from @beno

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@beno also got me a new set of clutch housing bolts, as he informed me that they were one-time-use. Locktite'd and torqued to 14ft/lbs.

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New Koyo throw-out bearing. And newly cad-plated clutch fork ball pivot. Also new clips that hold the fork to the throw out bearing carrier; purchased from, and recommended by @beno .

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Clutch is in!
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No rear disc's?
 
No rear disc's?

No. I'm redoing the entire brake system though, with the new extra power brake booster from Racer65's Unobtanium store. I've been told and have read that rear disks will not be necessary with the upgraded booster.

I had them on my 1968, and while it solved one problem (stopping) it introduced a new one (e-brake barely working).
 
E-brake should be on the transfercase
 
Yes, duh. I wasn't thinking. But still, I'll keep the drums with the extra power booster.
 
Drums are fine with smaller tires as long as you know how to adjust them properly (not the same as a US car) and don't mind doing it often (not self adjusting). I'm a RDB guy, though.
 
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Had no idea the pressure plate retaining bolts were one time use. What the reasoning there?
 
Had no idea the pressure plate retaining bolts were one time use. What the reasoning there?

They're not. That's an old sales trick he learned from Cdan.
 
Called up @orangefj45 and got my power steering conversion sorted.

Ordered:
Pump mount
Box pedestal
Pulley
Belt
and 4 degree shim kit for my lift
 
Looking forward to seeing more progress pics!!!!

Keep up the great work.

:beer:

Georg @ Valley Hybrids & Cruiser Brothers
 
Not much today. Installed pedestal from Georg, and the PS bracket. Also took apart the gear reduction starter, cleaned it up, blasted, and painted a few parts, rebuilt, cleaned up the wiring and installed new marine grade shrink tubing, and installed.

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I'm going to be spending the next couple of days redoing the tranny and transfer case. Lots of bolts to be installed, lots of nooks and crannies to be cleaned, new boots, bushings, etc. I think it'll take some time to do. I think the finished product will be beautiful though.
 
looks great. if only i had the time.....

Yeah man, I sure thought you'd be done by now. I keep thinking "hell, didn't Lou say he'd need this hoist back in just a week or two?"
 

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