Sasquatch's 1980 FJ40 Basketcase Build

[FJ62sasquatch]

I spent all day Sunday loading up my (new to me) 40 on a trailer and hauling her to the house, my father seems to think I have bought a nice lawn ornament... but I think otherwise...

She is a 1980 FJ40, with a hard top from some other model, not sure of the year, there are countless issues besides the hard top... most note-ably the fact that she doesn't run! lol I paid $2500 for her and it was worth every penny.. she doesn't have a name yet.. but in due time she will!

A little about me, I'm a High School senior, graduating in May! and this is my summer project/college DD! I have a red 1988 FJ62, but I shutter to think what college life would do to her... so this way I get another cruiser, and get to learn a few things too!

I'll post some pics in a moment... Tomorrow I am going to strip the interior seats and really get her clean enough to get an idea of where to start.. and get into the engine bay a little!

First, I'm gonna make sure that all the lifters lift and all the rockers move and what not... and make sure all moving parts are in good shape and where they need to be!

Then, I'm going to get the engine "wired" up and put 12v to it hopefully this weekend and get compression tests done saturday.. if its cylinders 3 & 4 without compression... oh yea remember me saying it doesn't run ..... then a new head gasket and rebuild the carb... I believe its a weber 32/36 but I digress, I'll try and drop the tank before I get it trying to run... any ideas of what to use in the tank to clean it out before re-attaching it?

 

[FJ62sasquatch]

Pics....

 

[coinoperated40]

Tupperware and tin cans, One of the best ways to transport parts to a new home. I personally like the top cut out of a plastic milk jug, the handle helps with my old hands.
Anyway, looks like a good start.
Shane

 

[FJ62sasquatch]

That's part of my plan tomorrow, to get all that out and situated.. I know I have an old manifold and a tire carrier... And I think all my parking brake parts are there as well.... Here's hoping!!

Oh and I need to connect this again... Gear shifter

 

[FJ62sasquatch]

The story with the engine is that the PO had bent a valve and then had the engine redone... Afterwards, he put everything back together and had no compression in two cylinders and lost interest after buying a 80... This sounds like a head gasket issue to me ... I'll know more tomorrow and this weekend I'll put 12v to it... And hope for the best

 

[Toybota]

Looks like a cool summer project. Good luck and keep us updated.

 

[FJ62sasquatch]

OK guys.. I NEED HELP!!!

I stripped the interior (not much anyway lol) and I vaccummed out the floor... it seems I have some wierd sort of factory insulation... I think I saw something about dry ice and a rubber mallet to remove this, thoughts??

anywho.. after I got the gear shifter back in (4spd) I STILL could not shift... yes I had the clutch pressed in... so my thought was "Oh, maybe it isn't seating in the trans correctly.. let's take off the top cover and check and see if anything is in there".... not a good idea... I got it off the first time without a hitch... and I moved the shift head around, then I put it back together and it seemed to go into 1st and 2nd and reverse, but not 3/4?? Also, It didn't have to have the clutch down to shift??? Is that a sign of it not engaging the gears? anyway, I took it off again and DROPPED A DETENT SPRING IN THE GEAR BOX!!!!!!! so that blows anywho, what am I going to do now? drain the gear box and get the spring out? any advice on the shifting or lack there of? and my spring problem?

ok, so after that fiasco... I pulled the plugs, and distributor cap and valve cover, and then I tried to turn the engine over... I was pushing on the belt and it wouldn't budge.. so I rigged the clutch down with a brick, and I'm not sure if it made it easier but I was able to turn it by grabbing both sides of the belt and pull it.. all the lifters are moving so thats a plus!!

the parking brake... I have all the cab parts and pull wire coming from the brake, but I don't know how to connect them.. I'm going to consult the SOR diagrams tonight...


any help is appreciated guys! I REALLY want to get this thing running by may 25th!!! thats when I graduate!!! here's hoping!!

 

[FJ62sasquatch]

another specific question I wanted to ask! should I be concerned about the engine not turning well? should I turn it clockwise or counter clockwise??

 

[Tireguy87]

Your gas tank can be boiled out at your local radiator shop. That's what I did. Some will say put some kind of solvent in it and shake it around with rocks or something similar to break up caked on gunk and old gas.

How long has the engine been sitting? Was it left with oil in it? If it ran when parked, you should be able to turn it over now. If turning by hand, turn clockwise. If it's been sitting, put some magic mystery oil in all spark plug holes and let it soak in a day or more. If it hasn't set up long, put a hot battery in it and give it a try.

As far as the tranny goes, I'd drain the fluid and dig that spring out if you can. Otherwise it could end up somewhere you don't want it to be. It's normal to be able to shift without the clutch engaged. Make sure you have your shifter fully seated into the top plate. Why was it removed in the first place?

Hope this helps.

 

[FJ62sasquatch]

The engine has been sitting since 2010... And oil was in it! Everything moved fine when I moved it, and after some searching I read where it should be stiff to pull the engine by the belts... So I'm not so worried... I'm gonna get a buddy to help this weekend and I guess it'll just be time to drain the Trans and maybe the engine oil too.... I'm gonna get a battery too because the dizzy is seated and everything seems to be moving correctly... Any other reasons why I would only be getting 3 gears??? The gear shifter was removed by the PO for whatever reason... This was the first day getting into it...

The transfer case shifter was removed too and I have it connected with the washer and nut on "top" connection Which is the H2 to H4 selector but the H4-N-L4 seems to be missing a cotter pin or something... I can't seem to find any info on it...

Hopefully, after the battery I'll get some compression numbers and it'll be determined to be a head gasket issue here's hoping!

 

[FJ62sasquatch]

Also how much marvel oil in each cylinder?

 

[MOTOV8R]

Shifters were likely removed when the engine was pulled and the tranny and tcase were attached. Probably never re installed when everything was put back.

 

[FJ62sasquatch]

Below is a picture of the shifters... labeled for the sake of simplicity, LEFT - MIDDLE - RIGHT
which way should these shifters move? Should they all move up and down, and the outer two should move right and left? It just seems like I wasn't shifting correctly and was limited to 3 gears, (1,2,R?) thoughts on this?

EDIT: NOT MY TRANS PICTURE ONLY FOR REFERENCE

 

[bhmmapping]

The transmission was probably in gear when the shifter was pulled. You need to put it back in neutral position before you put the shifter back on.

 

[justbecause]

Shifters were likely removed when the engine was pulled and the tranny and tcase were attached. Probably never re installed when everything was put back.

bingo.

Below is a picture of the shifters... labeled for the sake of simplicity, LEFT - MIDDLE - RIGHT
which way should these shifters move? Should they all move up and down, and the outer two should move right and left? It just seems like I wasn't shifting correctly and was limited to 3 gears, (1,2,R?) thoughts on this?

is that your transmission? what is red?

 

[SouthBostonFJ40]

Maybe this has been pointed out before, but you have an early bib with indicator lights with a later square bezel. I wasn't aware that the later bezel would fit the early bib. How'd they do that?

 

[justbecause]

Maybe this has been pointed out before, but you have an early bib with indicator lights with a later square bezel. I wasn't aware that the later bezel would fit the early bib. How'd they do that?

I cut holes in the bib to fit the earlier turn signals, I thought it looked cool.

 

[SouthBostonFJ40]

I cut holes in the bib to fit the earlier turn signals, I thought it looked cool.

Oh, is that your old truck?

 

[Michael Hanson]

For the $ its nice cruiser. Have fun. MIke

 

[justbecause]

Oh, is that your old truck?

It is, I am glad after a couple years of neglect that she went to a caring home...