Rebuild 74 FJ40 RHD from Down Under - 2F to 2H to 12HT - 40 series Axles with 80 series Coils

[watrob]

The parts bench is slowing getting less cluttered as I slowly put back together the engine. The hardest part is once you get to the bolts & nuts it's the cleaning of them that takes up your time. You can see what they look like in the photo on the thermostat housing, I will pull off, clean, etch & paint them before fully installing the housing.

 

[watrob]

You can see I have cut of the power steering pump part of the bracket from the newer HJ60/HJ75 series engine mounts (photo of blue engine mount) and welded it to the older HJ45/47 engine mounts. This is so I can mount the power steering pump from the 12ht or for a 2H engine.

 

[watrob]

Just finished the alternator, this is a external regulator model to suite my current wiring loom in the 40!

 

[watrob]

My Lokka just arrived, have installed these before, very simple. This one is going in the rear of the new chassis. I pickup the Harrop/Eaton E-Locker tomorrow for the front diff.

 

[chappohj47]

Looking good mate love the engine
Looks like you got some good presents

May I ask how much the alternator is as I am looking for a new one soon

 

[watrob]

All the 4x4 wrecking yards have them here for around $110 external regulator and about $180 for internal regulator versions. I always have a spare one laying around as backup. 2 or 3 hours work cleans them up.

 

[watrob]

Ok spent another hour on the 12ht rebuild this evening after work. It just takes so long, I blew a cleaning oil under pressure thru the IP diesel fuel lines to make sure no debris was inside the lines which could block the injectors.

I have found that building the engine from the bottom up works well, but the time cleaning, priming & painting bolts and nuts is the most time consuming part of the rebuild.

 

[watrob]

Did another couple hours on the rebuild this evening, the turbo is nearly ready as is the exhaust manifold to be bolted on. This side of the engine is 95% completed, just the power steering pump, vac lines and starter motor and few other minor bolt on's.

 

[watrob]

Now this side of the 12ht there's a few nights work yet to be done?

 

[Dale]

That engine is beautiful!

 

[watrob]

Just spent another couple hours on the 12HT, the exhaust manifold has been ceramic coated a dark grey, also on the inside (its believed ceramic internal coating can reduce heat by 30%), removed the old rings and installed the new teflon type o'rings and then the metal rings on top. The o'rings under the metal rings turn to ash.

 

[watrob]

Slowly getting this side of the engine completed. The turbo is just sitting in position at the moment until I get all the order right of install of all the parts. Again the bolt cleaning & painting takes up most of the time.

Also I need to check, for some reason my exhaust manifold is held on by 12 bolts with washers, not studs in the cylinder head with nuts & washers as mentioned in the engine manual?

On the exhaust side of the turbo both inner & outer are ceramic coated.

 

[lostmarbles]

Reminds me somewhat of the famous "technicolor engine build" done by Trollhole.

Are you planning on "showing" this cruiser when it is finished? (It certainly wouldn't look out of place in a car show with a big mirror underneath. .... Probably easily win trophies in such an event too )

 

[watrob]

Took a break from the engine rebuild and finished off preparing the air cleaner and having it painted. Last item on my list will be a left hand battery tray, need to find one from a BJ42 as my current 40 has a right hand one?

 

[Dale]

I love the detail thats going in to this build. keep the pics coming

 

[watrob]

What comes in a grey box and fits 40 series?

 

[watrob]

Had the rear hubs lathed so to fit disc rotors!

 

[watrob]

As I am on the beach all the time I use solid rotors for the rear (disregard the old seals left in the hubs)

 

[watrob]

Disc fits neatly on hub.

 

[watrob]

As the longer wheel studs are a little to long, instead of individual washers this spacer is used.