Builds Project Pikachu: 1977 FJ40 (2 Viewers)

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4-degree shims just showed up from @orangefj45. Looking forward to getting these installed.

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My passengers are getting tired of staring through a broken windshield. Since no glass places carry this windshield any more (and my Toyota guy can't ship glass), I've decided to remove it myself and have a new one cut by a local shop.

The search function isn't working on 'mud today, so I devised a removal method on my own. Worked fine.

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Once the seals are loose, it can be pulled out from the top and pretty much pops out. It broke in a couple more spots because it already had deep cracks throughout, but should be good enough for the new template.

Off to the glaser.

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I installed the new windshield today. Much thanks to @Texican for his installation thread. Very simple process overall. I also replaced the four wiper motor cover bolts with new stainless ones.

It is very, very nice having a clear windshield in this thing.
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I put about 100 miles on the rig today. I'd like to make this thing as highway-worthy as I can, especially during trips where I drive it to my destination. Running her hard as a daily driver will hopefully flush out any latent mechanical issues. So, I developed a leak at the clutch master cylinder, which is probably a good thing. Better now than on a trail somewhere on the next adventure.

Also, I'm still dealing with a driveline vibration coming from somewhere, so I pulled the rear driveshaft after 25 miles and drove in front wheel drive the rest of the day. Drives great no with issues when only the front is engaged. I'm gonna need to read more about the cause, but balancing the rear driveshaft may be the next step. Regardless, it still needed the shims.

Another day of classic 40 ownership. Gonna get Pikachu dialed in nicely after a while.

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I put about 100 miles on the rig today. I'd like to make this thing as highway-worthy as I can, especially during trips where I drive it to my destination. Running her hard as a daily driver will hopefully flush out any latent mechanical issues. So, I developed a leak at the clutch master cylinder, which is probably a good thing. Better now than on a trail somewhere on the next adventure.

Also, I'm still dealing with a driveline vibration coming from somewhere, so I pulled the rear driveshaft after 25 miles and drove in front wheel drive the rest of the day. Drives great no with issues when only the front is engaged. I'm gonna need to read more about the cause, but balancing the rear driveshaft may be the next step. Regardless, it still needed the shims.

Another day of classic 40 ownership. Gonna get Pikachu dialed in nicely after a while.

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My BJ had the same leaking clutch master issue when I got it. The fluid stripped the paint off the firewall.
 
Once the seals are loose, it can be pulled out from the top and pretty much pops out. It broke in a couple more spots because it already had deep cracks throughout, but should be good enough for the new template.

Off to the glaser.

Next time, get in the seat, place feet against windshield and push it out.
 
New clutch cylinder showed up today and I popped it in. The slave had recently been replaced by a P.O., so I am leaving it as is. The fluid was still clean and clear.

However, I missed the fact that I still have the old rubber line from the firewall to the slave, so I'm going to replace that before refilling the system.

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Stumbled across this thread while researching driveshaft issues last week. After reinstalling it with the yokes "aligned", it completely solved the vibration issue and I learned something new in the process:

Alignment of driveshaft yokes & mystery vibrations

Mud is one hell of a great resource.
 
Stumbled across this thread while researching driveshaft issues last week. After reinstalling it with the yokes "aligned", it completely solved the vibration issue and I learned something new in the process:

Alignment of driveshaft yokes & mystery vibrations

Mud is one hell of a great resource.

Cool I need to bookmark this, I had already screen shooted your shim fix to come back to when I get some cruiser time.
I ve got a 4in lift with 33s, certain situations like slowing down that feels like a up and down bounce ride. I have narrrowed down to what I think is axle wrap type vibrations.

Anyway can't wait to see your next outing in the cruiser.
 
I also want tighter steering for better road worthiness. The steering box has huge amounts of play, so I found a place in Fort Worth that can rebuild it.

Yanked it today. This thing leaked like a sieve and had years of mud caked up on it.
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Since Pikachu is out of commission for a week or two, I took my '76 for a spin today. I've had this one for going on 10 years. Spent about 6 months searching for a rust-free, all original cruiser. Even then, before these got to be so popular, it was hard to find a really clean one with original paint and no rust. I was a long-time FJ60 guy and was determined to find a 40.

I flew out to Phoenix with an envelope full of benjamins, took a shuttle to Prescott, then squeezed for 2+ hours on the front bench seat of a 1990s F250 with the owner, his wife, and dog to their second home in a ghost town in the desert. The 40 resided there and was used for church (yes, really) and Grand Canyon trips. It was/is incredibly original, down to the warranty cards and all records. I'm not sure what I would've done if the 40 didn't meet my expectations when we showed up. I had no way back!

I have an interesting thread on mud somewhere about how the deal fell apart due to the owner's 30-year attachment to the truck, but things eventually worked out about a month later.

Anyway, driving it solo across the Arizona desert was a fun story and probably deserves it own thread one day.

Ive raised my kids in this rig and have taken it on quite a few wonderful trips.
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