Builds Rebuild of Trusty (1 Viewer)

[POPO AGIE]

-The cotter pin was like threading a needle with pilers. The pins were SS so that may be why I could not retrieve them with a magnet, if I could not feel them..

 

[POPO AGIE]

Picked up the shock tower from the machine shop.

 

[MatthewMcD]

-The cotter pin was like threading a needle with pilers. The pins were SS so that may be why I could not retrieve them with a magnet, if I could not feel them..

The next owner will find them.

 

[POPO AGIE]

The next owner will find them.

After I am dead and most likely it will become my Sons.

 

[POPO AGIE]

Set up so the top hole could be transferred punch for drilling. The clamp was holding to the frame and the 2 magnets provided the extra hands. lined up with the shock bolted to the axle and eye balled the rod between the eyes.

Punch mark for first hole to be drilled

Had to bend the lower shock eye to help lining up with the top of the shock tower and the shim on the back of the tower was setting flat on the support plate for the bump stop.

Got the top hole drilled out and bolted the tower with the top bolt hole and transfer punched the bottom hole

Punch mark for bottom hole

Both holes drilled

 

[POPO AGIE]

Both holes drilled

Bolted up the shock tower

Bolted the new fender support plate

Removed the tower to open the holes in the shock towers so 1/2" hardware will work top and bottom

 

[clrussell]

I need to go back and figure out your brake setup.

 

[POPO AGIE]

I need to go back and figure out your brake setup.

What do you want to know? This is the kit I bought and then I cut the shim off of the adapter and got brake line supports from Trail Gear.

The rear I reused my my front hubs and then just used front rotors and calipers after I converted the FJ60 axle to full floater.

 

[clrussell]

What do you want to know? This is the kit I bought and then I cut the shim off of the adapter and got brake line supports from Trail Gear.

The rear I reused my my front hubs and then just used front rotors and calipers after I converted the FJ60 axle to full floater.

View attachment 3827524

Easy enough. I wondered if you pieced it together or got a kit.

 

[POPO AGIE]

Easy enough. I wondered if you pieced it together or got a kit.

This kit uses IFS wheel hubs and the wheel flange is moved out 1.5" so the track will be 3" wider then using FJxx wheel hubs. I when with this kit so the track would match the FJ60 rear axle.

 

[POPO AGIE]

Set up to use the winch on the truck to rotate the FJ40 to work on the PS shock tower. Didn't want to work with my back towards the wall.

Removed the wheel and prepped to remove the fender

Dripped the bib

Removed the fender because the new shock tower is 2" taller and will not fit in the inner fender where the stock tower was

 

[clrussell]

This kit uses IFS wheel hubs and the wheel flange is moved out 1.5" so the track will be 3" wider then using FJxx wheel hubs. I when with this kit so the track would match the FJ60 rear axle.

I have read about this before. Thank you for clarifying

 

[POPO AGIE]

The bolts had been sprayed with Kroil and they came right out no cutting or drilling

Cleaned the frame with a wire wheel and will paint later

Chased the thread

Put the new fender support on for location with new hardware

 

[POPO AGIE]

Starting position of the lower shock mount

Use magnets and a c-clamp to secure and check alignment with a shock and transfer punch both holes

Final position of the lower shock mount after checking with the shock and eye balled in

Transfer punch marks

Set up the mag base after trying to drill both by hand the lower hole work hardened and could not drill by hand, bits are getting dull

 

[POPO AGIE]

Worked through the bottom hole and drilled out to 1/2" and inserted a bolt

Moved mag base and finished drilling the upper hole and inserted both the bolts with shock tower

The bolts would not insert from the inside so I used a step bet to camphor the holes on both sides to remove the attached cuttings
Installed the wheel an set back down on the skate

Put the fender back on and bolted to the bib to help with alignment getting the bolts in the fender and done for the night

While working on the shock towers I found the fan shroud was loose because the self tapping screws did not hold in the radiator support and will pull the cooling stack and drill and bolt this time

 

[pb4ugo]

Are you sleeving the holes going thru the frame for the shocks and steering box?

 

[POPO AGIE]

Yes I ordered 18" stick of DOM tubing and have different bolts coming also.

 

[POPO AGIE]

Today removed the bib to pull the cooling stack to secure the lower fan shroud

Replaced the self taping screws with a M6 bolts

While the cooling stack was out of the way I installed the serpentine belt and was the first one I have done. I used my long handled flex 1/2 drive ratchet and it took the entire travel from the inner fender to the fan hub to get the belt on to the alternator pully

Bolted the new hones on each side of the radiator support

 

[POPO AGIE]

Once the cooling stack was back in and the bib installed we used the tractor to push back as far as we could

Used the spare against a pole to stop any further movement

This was a test to see if I could park my truck in front of it and still have room to work on each side

 

[jim land]

Looking at your pics , you will need longer shackles, the front one max out before the springs got flat , through the frame longer shackle can be a good altenative to get more travel and keep the spring level .

The rear one will invert for sur and are probably too short for those lift spring