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- #621
Since everyone likes Toyota bling. (except Onur)
Builds Roma's 78 fj40 gets a refurb (5 Viewers)
- Thread starter roma042987
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- #622
Reinstalled the seals and lubed them up with some synthetic grease.
I used blue loctite on the plate screws and staked the back side with a spring loaded punch.
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- #623
This throttle arm was damaged and I didn't take a photo of it but I straightened it, ground the fatigued metal nearly through on the bottom side then welded it back up. I flap disced it back down and then laid another bead down on the top side.
I started organizing the split case parts as well. Reinstalled the fork on the 4wd selector shaft and pressed the stud back into the shifter arm.
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- #624
Split case is as assembled as it can be in prep for install behind the h55.
@roma042987 seems like you are in a gold bazaar in Dubai. Carry on.
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- #626
I'll take it! In all seriousness, it's always been function over fashion for me. That's also why this 40 is powder coated instead of sporting a flashy paint job. The zinc plating has really good corrosion resistance and is the best option unless you want to buy all new hardware. Alot of the hardware has superseded over the years however and the new part while may fit the hole doesn't always fit like the original hardware. I found this out a few years ago when I forgot to replate a few bellhousing bolts on a real pretty 12ht. I figured I'll just buy new bolts since it was only a few but, the new bolts were too short and didn't yield enough thread engagement in my opinion.
I had this barb replated and reinstalled along with a new coolant hose.
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- #627
This project is going on the backburner for a while with an upcoming work trip.
Punch list of parts I need to get ordered/make:
Clutch kit
long spline input gear
Fan clutch
oil sender
belts
radiator
fitting for oil drain m20x1.5 to -12
turbo
turbo manifold
make a cross over pipe for the lower rad connection
make a rear heater pipe to go from the water pump to the back of the head (like on 3Bs)
parts to finish the front axle:
rotors
calipers
axles shafts
Other:
secondary fuel tank (maybe manafre)
New suspension (My other 40 build is coming along and I need to get suspension for it so figured I'll use the suspension and front axle from this truck since it is getting an upgraded axle)
I think that covers it...I'll pick up working on my 75 fj40 in Arizona next week finishing up a power steering conversion and a FST install. I really should make a thread for that rig. Also plan on getting over to 4+ to pick up a trans crossmember for the other diesel 40 build I have going here in Alabama. I was really hoping to get the thirds out of my 60 so I could get them dropped off with Ken (ZUK) this trip out but simply ran out of time....too many projects.
Punch list of parts I need to get ordered/make:
Clutch kit
long spline input gear
Fan clutch
oil sender
belts
radiator
fitting for oil drain m20x1.5 to -12
turbo
turbo manifold
make a cross over pipe for the lower rad connection
make a rear heater pipe to go from the water pump to the back of the head (like on 3Bs)
parts to finish the front axle:
rotors
calipers
axles shafts
Other:
secondary fuel tank (maybe manafre)
New suspension (My other 40 build is coming along and I need to get suspension for it so figured I'll use the suspension and front axle from this truck since it is getting an upgraded axle)
I think that covers it...I'll pick up working on my 75 fj40 in Arizona next week finishing up a power steering conversion and a FST install. I really should make a thread for that rig. Also plan on getting over to 4+ to pick up a trans crossmember for the other diesel 40 build I have going here in Alabama. I was really hoping to get the thirds out of my 60 so I could get them dropped off with Ken (ZUK) this trip out but simply ran out of time....too many projects.
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- Thread starter
- #628
Putting this case together the other day I noticed that one of the plugs had some corrosion at some point. I don't think it would have caused any issues but it bothered me so I replaced both plugs.
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- #629
RevISK
SILVER Star
Wow.
Just powered through two of your threads and I feel like I’m sitting with an Astro physicist listening to all the amazing stuff that makes the universe work and I just say, “ There’s the moon!”
Truly astounding.
I got my 40 running after it sat for 30 years, I have no idea how or what I did, but I got it running.
so, greetings from the daycare center over here to the upper echelon of master classes.
Thank you for the effort of posting all of this,
Ian
Just powered through two of your threads and I feel like I’m sitting with an Astro physicist listening to all the amazing stuff that makes the universe work and I just say, “ There’s the moon!”
Truly astounding.
I got my 40 running after it sat for 30 years, I have no idea how or what I did, but I got it running.
so, greetings from the daycare center over here to the upper echelon of master classes.
Thank you for the effort of posting all of this,
Ian
- Thread starter
- #631
Thanks for the kind words.
I've been piddling with my cruisers in Arizona the last couple of months and the weather was just too nice today to not get the 40 out. I wrangled the car seats in and put a bit over a hundred miles on her riding back roads and pastures. Took my two year old for his second range sess, this kid hit a t-post from 25 yards on his third shot.
RevISK
SILVER Star
@roma042987 the thing I can relate to is road trips. I’ve driven my tundra almost 200,000 miles just exploring. You’ve ramped up the inspiration to start doing that in my 40. Thank you.
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- #633
I'm rehoming the 3b out of my 40 so have to fast pace this conversion. I'm going to pull the engine next weekend so yesterday I spent some time on the 15bf. I got this crazy looking oil pan off to reveal an even odder looking pick up assembly.
I had read somewhere researching this swap that the 15bf doesn't have piston oil squirters while the 15bft does, that didn't sound real plausible to me and now I can displace those remours as incorrect.
I had read somewhere researching this swap that the 15bf doesn't have piston oil squirters while the 15bft does, that didn't sound real plausible to me and now I can displace those remours as incorrect.
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- Thread starter
- #634
Somehow I didn't realize I'd need a new pickup since this was already a rear sump engine however, did recall reading that a 3b pickup would work. As luck would have it, this spare 3b short block had found it's way into my garage literally less than two weeks ago.
Got lucky dodging that can of worms! It fits.
I pulled the rear seal retainer and cleaned it up in the vapor hone.
Got lucky dodging that can of worms! It fits.
I pulled the rear seal retainer and cleaned it up in the vapor hone.
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- #635
- Thread starter
- #636
I need to get a pickup tube gasket for this thing but it all jives, and I stuck the pan on just to keep the dust out of everything. I actually want to drill this block at the turbo oil drain boss for a turbo drain while I have this pan off. It appears like I'll need to drill through about an inch or two of cast iron in that spot particular spot if I go this route. The alternative would be welding a bung on this pretty new pan.
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- #637
Sunday I drove the 40 into the garage under 3b power one last time. My two year old spent the day with me tearing it apart. I couldn't decide whether I wanted to pull engine and trans together or pull one or the other first. I ended up pulling the driveshafts, all the shifters, and boots and then decided to pull the engine alone. I tied a ratchet strap under the spilt case to hold the trans/tcase assembly in position on the crossmember. Between 7 diesels and 4 h55 split case combos in my one car garage, quarters are tight so, I decided it would be best to get the 3b out and off to it's new home before I pulled the trans.
This 3b has served me well over the years, it had never left me stranded with travels across all over even the remotest parts of the western U.S.
Ironically, or perhaps fatefully it came out of an 85 bj70 and now its going back in another 85 bj70. I removed the turbo and reinstalled the original manifold and 70 series power steering pump before I delivered it to it's new owner today.
This 3b has served me well over the years, it had never left me stranded with travels across all over even the remotest parts of the western U.S.
Ironically, or perhaps fatefully it came out of an 85 bj70 and now its going back in another 85 bj70. I removed the turbo and reinstalled the original manifold and 70 series power steering pump before I delivered it to it's new owner today.
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- #638
With the engine out of the way I need to drop the trans/tcase assembly. I have the new case ready to be installed but I want to give the trans a good clean, reseal, and fresh coat of paint first.
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- #639
Last night I dropped the trans. The PCV tube had coated it generously with oil.
I can't seem to ever have enough movers dollys for drivetrains so picked up another one at HF last night and decked it with some planks and 3/4 inch ply. I soaked it with wd40 last night to cut the grease and this morning gave it a good pressure wash. I keep putting off buying one but, I really want a heated pressure washer for this kind of work.
I can't seem to ever have enough movers dollys for drivetrains so picked up another one at HF last night and decked it with some planks and 3/4 inch ply. I soaked it with wd40 last night to cut the grease and this morning gave it a good pressure wash. I keep putting off buying one but, I really want a heated pressure washer for this kind of work.
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- #640
I put roughly 40k miles on the 40 since installing this tcase. The drivetrain originally had a vacuum tcase and I installed this 34mm case to have it fully manual. At the time I didn't rebuild it and didn't even use a gasket between the case halves, (I used hondabond) I didn't know at the time that the tolerance changes slightly when the gasket isn't used. I dont remember if I checked the preload on the out put shaft but theoretically it should have been too tight without a gasket. Surprisingly this thing still looks spotless on the inside and all the gears look excellent. I'll clean this one up in the parts washer and will need to get another rebuild kit to have it on standby.
