EDITED FOR QUICK(er) READING:Quite a few of you have probably seen my random questions and a few issues here and there for the last couple years on this great site. Like most of you, this is my go to web site for info and entertainment as well as dreaming.
A little background on me. I like old things and anything with an engine. I have a job at a family owned limo Manufacturing company. I have access to lots of auto parts accessories and anything needed to build or work on autos.
Anyways, I am on my 3rd FJ62. My first has been my daily driver for the last two years. It runs well, looks good and I maintain it. I try not to mess with it too much and I repair/replace things as needed. Don't mess with a good thing, right?
Bought fixed up/painted and sold an 88FJ62 recently...
That was supposed to be the wife's cruiser, but life got in the way and I sold it for a nice little profit. Fast forward about 20 hours, yes hours, and I was the proud new owner of another very similar 88 FJ62 also in champagne. This one though has a sweet pinstripe. The whole thing is super faded and has some rust to contend with. It is literally growing moss on it from sitting so long. Other than that, it didn't run, had a flat tire, chip in windshield, suspension is shot, exhaust is swiss cheese, Power steering was not working, Horn not working, A/C obviously not working, heat works, bumpers are fair, Left rear brake line not attached and capped, lots of the lights did not work or were totally broken and it was literally full of sand from being a beach wagon for the PO the last 13 years. But for a beach truck it has a very good frame, albeit with surface rust everywhere and some body rot.
So I got it for $1,400 bucks.. Some may say cheap, some may say fair price and others would have walked away. But... I got the disease, so I got it towed home.
I have done quite a few things already to the truck, but in order to keep track of my progress and contribute some entertainment value to this site, I am starting its own build thread. You will probably laugh at some of my repairs which is always fun and other repairs will be done right.
Here we go.
I picked up the truck about a moth ago from the previous owner in Kingston, Massachusetts. It now lives in Haverhill, Ma. Both Left side doors are pretty rusty beyond saving. I found 4 FJ62 doors on craigslist for pretty cheap, but they were on block island. So i convinced the seller to send them over on the ferry for me to pick up. Made an offer of $100 a door because they wanted far more and I picked them up from the ferry. When I found them waiting at the cargo dock they were in a large bin full of water on a rainy day... YAY! They still have glass, mirrors regulators, etc but no door cards or switches. No worries, I got that stuff already, I just need the doors. I will need the rear lift and tail gate at some point too, but will need to wait on those. Mine got some rust holes for sure!
Once I got it home, I charged the battery in it, turned the key and she wanted to start. the gas gauge was at empty, so I put some gas in. Turned the key, pumped the gas and she roared to life and all gauges worked. She didn't want to stay running and it was running pretty rough after probably 3 or 4 years of sitting. Got it to idle and went under the hood to have a peak. Immediately I noticed there was a soft fuel line squirting gas. I shut the truck down and started making a list in my head.
1. repair fuel line.
2. clean out the sand.
3. remove that mahogany deck furniture from the roof
4. see if it drives
5. fix power steering.
Once I repaired the rubber fuel line, I was able to start it and see if it moves... even with a flat front right tire. It moved and I parked it in a normal spot as the tow truck driver just dumped it in the middle of the driveway. I recalled I still have some old OEM wheels with tires on them. So I went and checked and a couple still held air. So I rolled it over and put it on. It now has 4 tires that hold air!
Next was to see how it dove down the road. As expected it was very bouncy due to very saggy leaf springs and tired shocks.
Then I found a new fuel filter in the box in the back of the truck and wrestled that in there.
EDIT: Half assed power steering fix below.. read on if you's like
I wanted to then see if I could get the power steering working again. The PO had to bypass the return hose under the rad due to a leak a while back, but that was fine. I put some Dexron type IV ATF in and it started to squeal until it got the right amount of fluid in there. It was swirling all around so I knew it was working or trying to. Hop in, popped it in drive and turned the wheel and it worked. Looked back under the hood and noticed the feed or high pressure side was leaking just before the steering box. Not wanting to shell out for new line and tear the whole front end apart to replace both high and low sides, I cut that hose out and replaced the line with an ATF fluid line to the steering box. I tried to attach the new high pressure line to where it connects at the line coming out from under the rad, but it has no barb. So... when I tried to turn the wheel without the vehicle in motion, the hose popped off and fluid went literally everywhere!!! So, I realized that wasn't going to work. Had to bypass under the rad. I then cut the high pressure soft line after the fitting coming out of the PS pump. Realized there was metal hard line in the soft line, so I would be able to put a barbed fitting in there. Took the 90 degree fitting out of the PS pump, lopped off the hose and flared the end of the fitting. Then screwed that back into the PS pump and used more ATF soft line over to the spot where I tried to tie in under the rad with another barbed fitting. Put like 3 hose clamps on each connection, refilled and it worked. Then I made the mistake of turning the wheel at a stop again and then showered everything is fluid again. More hose clamps once I connected it again. Has been holding for now until I get to the root of that someday.
So now I had a running driving 62. So I drove it around to the detail shop and vacuumed probably 50 lbs of sand out of it, no joke. I could now see the floor.
Then, I changed the oil and spark plugs because it needed it. Slightly better, but still idles a little high and wanted to stall in reverse. Checked out the cooling system once it was running, because now it needs to stay cool if it runs. It was nearly dry. Added some green 50/50 prestone all makes coolant and got the system purged of air after much burping and massaging... but never had to remove any hoses luckily.
I next decided I could not stand listening to this thing because it was so loud that when it was running I could not diagnose anything over the sound of the terrible exhaust. So I had someone remove the cats and re install the O2 sensors.. you probably saw my thread on this.... Also then realized that it was almost no quieter because the muffler was toast. So I bought a throaty sounding $30 Thrush muffler to pop in there for now(it was the cheapest option).
Then, the check engine light came on. Did the whole jumper wire thing and counted the blinking of the CEL and got codes 28 and 51. 28 indicated the #2 sensor. So with the help of some fine folks(you know who you are) I checked the wiring and such for the sensors. All looked good so decided to just replace them in hope this would solve the issue. Fast forward a week and the sensors arrived. 30 minute job with a lift, got the old ones out and popped in the new ones. Then removed the EFI fuses for a few minutes, put it back in and fired it up. Check engine light went out at start up just like it should.. Good feeling! But, I still know its probably throwing code 51. Light is out though, good enough for now. Shes starting to run smoother now.
I still wanted to figure out why it was running a little rough and wanted to stall in reverse. I will change all the vac lines soon, but more importantly, in poking around I found my intake hose was cracked in the little accordion ridges that allow it to bend a little. I dont have an extra and they are not super cheap, so I just taped over it like everyone does at first. Immediately ran far better and was not stumbling or trying to stall. Still idles a little high from time to time. Cold start it will idle right at about 650 RPMs but has trouble settling back down sometimes after having hit the gas or driving it. I'll explore more on that later. Going after the big and easy stuff for now.
Next was some easy stuff because I'm not rich... I had a bunch of LED bulbs left over from trying to figure out what bulbs actually work and didn't work in my DD. Put in some nice LED's in the dash and shifter, cig light, HVAC and lower switches. All worked. Still need to replace domes with PFran's kit like in my DD. Its a nice little kit. Also the tach light is out and need to swap the rest of the gauge lights because I didn't dive in that far yet. But I have them should i decide to
With all interior lights working minus the domes because PFran kit needed, I started on the exterior lights. Luckily, I have access to a ton of different old bulbs and stuff, I was able to avoid the parts store. Headlights work, but not the high beams(high beam indicator works). More on that later. The front side marker lights(orange) did not work... the bulb socket and light housings were full on melted. Clipped those off and made Molex 2 pin connectors and new sockets. The lights worked but had no housing to mount them in because they were fully melted. Ordered new marker lights that when came in the bulb socket could not be removed like the OEM. So I took out my home made connectors and plugged in the new lights because I had left the OEM plug. Now those work. The rear side markers just needed bulbs and they cam right back on. Then at some point somehow I popped a fuse and almost all the exterior and interior lights went dead. I scratched my head for a while until I found the fuse. I had checked them all but must have missed one because when I checked again I found the popped fuse. All the lights came back.
Then started diving into the license plate light. EDIT: Turned out to be a bad ground... no ground through tailgate to body.. ran an external wire inside body.. light works now.
Bought transmission pan and filter gasket(have not had a chance to change these yet)
I plan on using Dex/Merc or Schaffer's AllTrans to refill. Hope that goes well and I do not cause any issues. I want to do this step as I have never done it before and I would think the wagon is in need. Shifting is fine as is and it doesn't have a clunk going into F or R. But I want this task checked off. I also have allen style magnetic plugs to put back in that I purchased a while back and never used.
Replaced tail lamp lens covers
That's about where I'm at currently but still need a lot of things done...
Soon will be
1. All brakes repaired/replaced
2. Transfer case and diff oil replaced
3. knuckle and axle seals (this will be my right of passage) this job makes me nervous as it will be time consuming and lots of parts coming off. I'm easily confused and forgetful
4. Purchase Tough Dog lift kit on sale!!
5. wheels and tires. Already picked out
Here are some photos for you to enjoy. Because whats a build thread without the pictures of the piles of crap we drag home and transform into desirable rigs? These first photos are of the day I sealed the deal on this beauty queen. Just as she sat.
A little background on me. I like old things and anything with an engine. I have a job at a family owned limo Manufacturing company. I have access to lots of auto parts accessories and anything needed to build or work on autos.
Anyways, I am on my 3rd FJ62. My first has been my daily driver for the last two years. It runs well, looks good and I maintain it. I try not to mess with it too much and I repair/replace things as needed. Don't mess with a good thing, right?
Bought fixed up/painted and sold an 88FJ62 recently...
That was supposed to be the wife's cruiser, but life got in the way and I sold it for a nice little profit. Fast forward about 20 hours, yes hours, and I was the proud new owner of another very similar 88 FJ62 also in champagne. This one though has a sweet pinstripe. The whole thing is super faded and has some rust to contend with. It is literally growing moss on it from sitting so long. Other than that, it didn't run, had a flat tire, chip in windshield, suspension is shot, exhaust is swiss cheese, Power steering was not working, Horn not working, A/C obviously not working, heat works, bumpers are fair, Left rear brake line not attached and capped, lots of the lights did not work or were totally broken and it was literally full of sand from being a beach wagon for the PO the last 13 years. But for a beach truck it has a very good frame, albeit with surface rust everywhere and some body rot.
So I got it for $1,400 bucks.. Some may say cheap, some may say fair price and others would have walked away. But... I got the disease, so I got it towed home.
I have done quite a few things already to the truck, but in order to keep track of my progress and contribute some entertainment value to this site, I am starting its own build thread. You will probably laugh at some of my repairs which is always fun and other repairs will be done right.
Here we go.
I picked up the truck about a moth ago from the previous owner in Kingston, Massachusetts. It now lives in Haverhill, Ma. Both Left side doors are pretty rusty beyond saving. I found 4 FJ62 doors on craigslist for pretty cheap, but they were on block island. So i convinced the seller to send them over on the ferry for me to pick up. Made an offer of $100 a door because they wanted far more and I picked them up from the ferry. When I found them waiting at the cargo dock they were in a large bin full of water on a rainy day... YAY! They still have glass, mirrors regulators, etc but no door cards or switches. No worries, I got that stuff already, I just need the doors. I will need the rear lift and tail gate at some point too, but will need to wait on those. Mine got some rust holes for sure!
Once I got it home, I charged the battery in it, turned the key and she wanted to start. the gas gauge was at empty, so I put some gas in. Turned the key, pumped the gas and she roared to life and all gauges worked. She didn't want to stay running and it was running pretty rough after probably 3 or 4 years of sitting. Got it to idle and went under the hood to have a peak. Immediately I noticed there was a soft fuel line squirting gas. I shut the truck down and started making a list in my head.
1. repair fuel line.
2. clean out the sand.
3. remove that mahogany deck furniture from the roof
4. see if it drives
5. fix power steering.
Once I repaired the rubber fuel line, I was able to start it and see if it moves... even with a flat front right tire. It moved and I parked it in a normal spot as the tow truck driver just dumped it in the middle of the driveway. I recalled I still have some old OEM wheels with tires on them. So I went and checked and a couple still held air. So I rolled it over and put it on. It now has 4 tires that hold air!
Next was to see how it dove down the road. As expected it was very bouncy due to very saggy leaf springs and tired shocks.
Then I found a new fuel filter in the box in the back of the truck and wrestled that in there.
EDIT: Half assed power steering fix below.. read on if you's like
I wanted to then see if I could get the power steering working again. The PO had to bypass the return hose under the rad due to a leak a while back, but that was fine. I put some Dexron type IV ATF in and it started to squeal until it got the right amount of fluid in there. It was swirling all around so I knew it was working or trying to. Hop in, popped it in drive and turned the wheel and it worked. Looked back under the hood and noticed the feed or high pressure side was leaking just before the steering box. Not wanting to shell out for new line and tear the whole front end apart to replace both high and low sides, I cut that hose out and replaced the line with an ATF fluid line to the steering box. I tried to attach the new high pressure line to where it connects at the line coming out from under the rad, but it has no barb. So... when I tried to turn the wheel without the vehicle in motion, the hose popped off and fluid went literally everywhere!!! So, I realized that wasn't going to work. Had to bypass under the rad. I then cut the high pressure soft line after the fitting coming out of the PS pump. Realized there was metal hard line in the soft line, so I would be able to put a barbed fitting in there. Took the 90 degree fitting out of the PS pump, lopped off the hose and flared the end of the fitting. Then screwed that back into the PS pump and used more ATF soft line over to the spot where I tried to tie in under the rad with another barbed fitting. Put like 3 hose clamps on each connection, refilled and it worked. Then I made the mistake of turning the wheel at a stop again and then showered everything is fluid again. More hose clamps once I connected it again. Has been holding for now until I get to the root of that someday.
So now I had a running driving 62. So I drove it around to the detail shop and vacuumed probably 50 lbs of sand out of it, no joke. I could now see the floor.
Then, I changed the oil and spark plugs because it needed it. Slightly better, but still idles a little high and wanted to stall in reverse. Checked out the cooling system once it was running, because now it needs to stay cool if it runs. It was nearly dry. Added some green 50/50 prestone all makes coolant and got the system purged of air after much burping and massaging... but never had to remove any hoses luckily.
I next decided I could not stand listening to this thing because it was so loud that when it was running I could not diagnose anything over the sound of the terrible exhaust. So I had someone remove the cats and re install the O2 sensors.. you probably saw my thread on this.... Also then realized that it was almost no quieter because the muffler was toast. So I bought a throaty sounding $30 Thrush muffler to pop in there for now(it was the cheapest option).
Then, the check engine light came on. Did the whole jumper wire thing and counted the blinking of the CEL and got codes 28 and 51. 28 indicated the #2 sensor. So with the help of some fine folks(you know who you are) I checked the wiring and such for the sensors. All looked good so decided to just replace them in hope this would solve the issue. Fast forward a week and the sensors arrived. 30 minute job with a lift, got the old ones out and popped in the new ones. Then removed the EFI fuses for a few minutes, put it back in and fired it up. Check engine light went out at start up just like it should.. Good feeling! But, I still know its probably throwing code 51. Light is out though, good enough for now. Shes starting to run smoother now.
I still wanted to figure out why it was running a little rough and wanted to stall in reverse. I will change all the vac lines soon, but more importantly, in poking around I found my intake hose was cracked in the little accordion ridges that allow it to bend a little. I dont have an extra and they are not super cheap, so I just taped over it like everyone does at first. Immediately ran far better and was not stumbling or trying to stall. Still idles a little high from time to time. Cold start it will idle right at about 650 RPMs but has trouble settling back down sometimes after having hit the gas or driving it. I'll explore more on that later. Going after the big and easy stuff for now.
Next was some easy stuff because I'm not rich... I had a bunch of LED bulbs left over from trying to figure out what bulbs actually work and didn't work in my DD. Put in some nice LED's in the dash and shifter, cig light, HVAC and lower switches. All worked. Still need to replace domes with PFran's kit like in my DD. Its a nice little kit. Also the tach light is out and need to swap the rest of the gauge lights because I didn't dive in that far yet. But I have them should i decide to
With all interior lights working minus the domes because PFran kit needed, I started on the exterior lights. Luckily, I have access to a ton of different old bulbs and stuff, I was able to avoid the parts store. Headlights work, but not the high beams(high beam indicator works). More on that later. The front side marker lights(orange) did not work... the bulb socket and light housings were full on melted. Clipped those off and made Molex 2 pin connectors and new sockets. The lights worked but had no housing to mount them in because they were fully melted. Ordered new marker lights that when came in the bulb socket could not be removed like the OEM. So I took out my home made connectors and plugged in the new lights because I had left the OEM plug. Now those work. The rear side markers just needed bulbs and they cam right back on. Then at some point somehow I popped a fuse and almost all the exterior and interior lights went dead. I scratched my head for a while until I found the fuse. I had checked them all but must have missed one because when I checked again I found the popped fuse. All the lights came back.
Then started diving into the license plate light. EDIT: Turned out to be a bad ground... no ground through tailgate to body.. ran an external wire inside body.. light works now.
Bought transmission pan and filter gasket(have not had a chance to change these yet)
I plan on using Dex/Merc or Schaffer's AllTrans to refill. Hope that goes well and I do not cause any issues. I want to do this step as I have never done it before and I would think the wagon is in need. Shifting is fine as is and it doesn't have a clunk going into F or R. But I want this task checked off. I also have allen style magnetic plugs to put back in that I purchased a while back and never used.
Replaced tail lamp lens covers
That's about where I'm at currently but still need a lot of things done...
Soon will be
1. All brakes repaired/replaced
2. Transfer case and diff oil replaced
3. knuckle and axle seals (this will be my right of passage) this job makes me nervous as it will be time consuming and lots of parts coming off. I'm easily confused and forgetful
4. Purchase Tough Dog lift kit on sale!!
5. wheels and tires. Already picked out
Here are some photos for you to enjoy. Because whats a build thread without the pictures of the piles of crap we drag home and transform into desirable rigs? These first photos are of the day I sealed the deal on this beauty queen. Just as she sat.
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