Build Roma's 78 fj40 gets a refurb

[roma042987]

I've been trying to work on this 40 from multiple angles feels like and trying to keep everything as organized as possible while doing so. Feels like organized chaos. The engine obviously is the biggest project. I also have a new front axle I've been building up for it with a front cable locker and upgrading to large pattern knuckles with aisin hubs. I also wanted to rebuild the split case behind the h55 since the unit in it now I put together with used parts over a decade ago. It's never given me an issue but I'd feel better if it had a rebuild kit in it.
With all these projects apart I was due for a run of hardware to take to get cad plated. I can't finish the axle until I get the hardware and same thing for the splitcase and engine. So I spent the the last three days organizing hardware and trying to get it cleaned enough for plating.

I also pulled the bell housing from my spare 3bii drivetrain to get eyes on the clutch. Interestingly enough it also has an 8 bolt flywheel but a smaller 260mm diameter compared to my 15bf which is 275mm. The clutch parts are not interchangeable. I suspect a late model 13bt clutch may fit the bill as the 3bii throw out bearing will not work on the Dyna clutch. The 3bii pressure plate will also not mate to the Dyna flywheel.

Since I'll be getting another round of hardware plated I decided to strip this spare splitcase of its hardware as well.

 

[roma042987]

I had initially considered building the split case on the above h55 but, decided to keep that combo alone. I know the h55 in my 40 is good and would prefer to run the above h55 in something before I build the case behind it. I bought it with no reported issues but who knows. Then I remembered I had another 38mm split case stashed away that I picked up somewhere probably 8 years ago. I dug it out and split it apart, after two hours with a pressure washer and then a parts washer I have it decreased enough for the media cabinet.

The gears are in great shape and I already have a terrain tamer rebuild kit for it in my stash. I do want to order a long spline input gear for it though just in case the h55 has some spline wear and for additional piece of mind.

 

[roma042987]

I never updated this thread with the front axle I'm working on for this truck so I'll try to do that now for future reference. I did all of this last year at some point.

This was a late model 40 housing my friend Tucker had blasted and por'd for me many years ago.

 

[roma042987]

Notching the housing for the locking puck

Donor e locker diff from an lx450

 

[roma042987]

The outside was a little dirty but the inside was in good shape.

Fully stripped and blasted the outside

 

[roma042987]

I powder coated it along with the flange. New crush sleeve and new inner and outer pinion bearings.

 

[roma042987]

 

[roma042987]

Front axle hardware, I like to organize it this way and snap a photo to aid in being able to separate it again once I pick it up from plating. When you end up with literally hundreds of bolts washers and nuts it's hard to figure out what goes to what without a visual aid like this.

 

[roma042987]

I wasn't happy with the shim thickness measurements first time around with an aftermarket knuckle centering tool so i bought a new toyota tool and got the same measurements.

 

[roma042987]

 

[roma042987]

Aftermarket tool

Toyota tool

That catches things up on my axle. I need to get my hardware plated for it so I can powder my knuckles and get them installed. I also still need to buy brake calipers, rotors, and some Longfields for it. I have new locking hubs, hoses, and toyota pads for it already.

 

[roma042987]

I did have one success story with my parts ordering. The megacruiser oil pan was actually manufactured and arrived from Japan. Since I'm not going to be modifying/repairing the pan currently on the engine, I don't have an opportunity to weld an oil return fitting into the pan. I really don't want to mess up the finish on this new pan by welding on it. I'm not going to turbo this engine right away but want to go ahead and prep it for an easy install at a later date. I plan to drill the block at the factory turbo oil drain location while the pan is off and I can control where the shavings go.

I put a hammer to the exhaust manifold heat shield and got it relatively straight and reinstalled.

 

[roma042987]

I took my venturi to a friend of mine to weld up the broken port for the PCV barb. Since I'll be adding a turbo on this engine I opted to seal this off instead of putting a barb back on it like it originally had. He was able to weld a plug into the port and even fixed the lip of the venturi as well.

 

[roma042987]

After welding additional material onto the lip he turned it back down on a mill. It's ready to be put back together now as soon as I get the hardware and throttle plate shaft back from plating.

 

[roma042987]

Whoops wrong thread

 

[roma042987]

Dropped off a bunch of hardware for zinc plating yesterday. Really need to get that back before I can put the throttle body back together and finish the prep for the tcase. In the mean time I went as far as I could with the tcase. I do want to order a long spline input gear for it since the h55 it's going behind has a few miles on it and it would be good reassurance.

 

[roma042987]

Main stack is done for the tcase.

I put some wheel bearing grease in the needle bearing for the front output.

Tcase parts came out pretty clean. In this photo you can see my new hired shop help. I pay him in candy but his work is questionable at this point.

He also tends to put his fingers where they don't belong as evidence shows here.

 

[roma042987]

I tapped the front case half to plug the hole for the unused bolt hole. I used a 1/4 NPT plig on this one. In the past I've used an m12x1.25 bolt as well.

He is proficient with the floor jack operation now and last night insisted on me helping him take the wheel off. I was putting the tcase together but he kept asking so I had to give him a hand but he buzzed it off himself with the 3/8 cordless gun.

 

[roma042987]

Took the glow screen apart today and got it cleaned up.

 

[roma042987]

Since the tcase is going to look so nice I figured might as well vapor hone the bell housing.