Build Saudi Arabia: 1982 FJ45 Troopy
- Thread starter boozewz
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Wow, what a story! Great canvas to start with, and phenomenal results to date! I'm re-restoring my 74-40; adding the detail parts and touching up the work the PO did.
LOVE your troops; more than enough room to go camping, carry the Mtb bike(s) and enough gear for a few days!
LOVE your troops; more than enough room to go camping, carry the Mtb bike(s) and enough gear for a few days!
- Thread starter
- #143
So we commence with the installation.
A shot of the stuff we got from the junkyard
They had spent quite a bit of time in caked mud and grease, so a thorough clean was in order
The 60 series disc we got were beyond rust. So we ordered a new set from the Toyota dealer
Also picked up the brake pads, and the PS fan belts
Time to remove the crank pulley. The GM pump system I had on already was running off one fan belt. The original 40 PS system has three slots, one for the water, PS, and AC
The crank pulley tool was already on hand, as @Mcladin has his work done at the same shop prior to my truck going in.
New pulley installed
A shot of the stuff we got from the junkyard
They had spent quite a bit of time in caked mud and grease, so a thorough clean was in order
The 60 series disc we got were beyond rust. So we ordered a new set from the Toyota dealer
Also picked up the brake pads, and the PS fan belts
Time to remove the crank pulley. The GM pump system I had on already was running off one fan belt. The original 40 PS system has three slots, one for the water, PS, and AC
The crank pulley tool was already on hand, as @Mcladin has his work done at the same shop prior to my truck going in.
New pulley installed
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- Thread starter
- #144
Original 40 series PS steering box installed.
PS pump now in.
Next up is an axle rebuild. I bought a complete rebuild kit from Marlin. I just liked the fact that it came all in one box kitted up ready to install.
Packing in new grease
Using the 60 series knuckles
Backing plates in
One thing we picked up was the newer 60 series (62 series?) disc do not have all the holes drilled into it to match the older 60 series knuckles. We did not end up drilling the 2 holes in, as I figured there are enough bolts (6) to secure the disc anyway.
Discs installed.
They just look so much better. Don't care if they work or not
So next up was we ran into an issue with the PS pump. It wasn't working. So took that off and went back to the junkyard to swap it. Believe it or not, they give warranty if the stuff you buy doesn't work, as long as its returned within a specified time frame, at no extra cost. So got another junkyard PS pump. Installed that, and again no luck. So we went a third time, and they pulled a PS pump off of a 60 series running a 3F engine. Bolted right in, (third time is a charm?). She turns like a dream. At least compared to the old GM pump I had.
As for the brakes, we ended up installing the original troopy brake booster and master. The master we got from the 60 series (front disc/rear drum) does not seem to come with a proportioning valve as seen in image below for master that are for front disc/rear drum set ups
Below is the troopy drum/drum set up I have
So currently the brake pedal has long travel, and feels a touch spongy. Previously when running the drums, pedal response was excellent, and firm. So I can't fault the booster. I guess the next step would be to install the 60 series booster, which won't fit as the clutch master is in the way. Apparently flipping the 60 brake booster upside down, along with adding a small spacer will get it to fit without touching the clutch master.
Stay tuned.
PS pump now in.
Next up is an axle rebuild. I bought a complete rebuild kit from Marlin. I just liked the fact that it came all in one box kitted up ready to install.
Packing in new grease
Using the 60 series knuckles
Backing plates in
One thing we picked up was the newer 60 series (62 series?) disc do not have all the holes drilled into it to match the older 60 series knuckles. We did not end up drilling the 2 holes in, as I figured there are enough bolts (6) to secure the disc anyway.
Discs installed.
They just look so much better. Don't care if they work or not
So next up was we ran into an issue with the PS pump. It wasn't working. So took that off and went back to the junkyard to swap it. Believe it or not, they give warranty if the stuff you buy doesn't work, as long as its returned within a specified time frame, at no extra cost. So got another junkyard PS pump. Installed that, and again no luck. So we went a third time, and they pulled a PS pump off of a 60 series running a 3F engine. Bolted right in, (third time is a charm?). She turns like a dream. At least compared to the old GM pump I had.
As for the brakes, we ended up installing the original troopy brake booster and master. The master we got from the 60 series (front disc/rear drum) does not seem to come with a proportioning valve as seen in image below for master that are for front disc/rear drum set ups
Below is the troopy drum/drum set up I have
So currently the brake pedal has long travel, and feels a touch spongy. Previously when running the drums, pedal response was excellent, and firm. So I can't fault the booster. I guess the next step would be to install the 60 series booster, which won't fit as the clutch master is in the way. Apparently flipping the 60 brake booster upside down, along with adding a small spacer will get it to fit without touching the clutch master.
Stay tuned.
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I'm not entirely sure, but on the 60-series was the proportioning done via a LSPV? (Load Sensing Proportioning Valve) That's how my T100 was... basically the valve is in the rear and sensing how much you've loaded in the back and adjusts the proporition of rear-brake accordingly. Might explain why you aren't finding one on the master.
In any case, you can keep your original 45 booster/master and just put your own proportioning valve in right at the master. A lot of the front-disk conversions here on Mud have done that... I think it's a must to greatly reduce the proportion to the rear once you've added disks to the front.
In any case, you can keep your original 45 booster/master and just put your own proportioning valve in right at the master. A lot of the front-disk conversions here on Mud have done that... I think it's a must to greatly reduce the proportion to the rear once you've added disks to the front.
- Thread starter
- #148
I thought I just need to get rid of the residual valve for the front brakes. I did not think a proportioning valve is needed for the rear unless I put discs in the back. Currently the truck stops but I don't feel its any better than when the drums were on the front. I was expecting a bigger difference. What would the proportioning valve do that would add to greater stopping power?
I ordered the 1975-1989 FJ40/45/55/60/62 front disc axle service kit. It had everything I needed and nothing went unused. Very happy with it.
https://www.marlincrawler.com/axle/front-axle-parts/service-parts
It came from the junkyard as well. You may not have spotted it in the box as my buddy had it with him in his box by mistake.
Wow! what a great thread. couldnt stop dreaming of having one. keep up the good work.
Thanks for the feedback on the barrage of questions... I need to find a good junk yard.
When you used the 60-series booster/master was it locking up the rear?
With the trooper booster/master does the rear lock up when you get on it hard?
I think you need a proportioning valve that focuses the brake effort into the front discs. For example...
https://forum.ih8mud.com/threads/brake-proportioning-valve-question.812137/
Reading through the threads I'm a bit confused... Some say you only need then proportioning valve if you go 4 wheel disc, that front wheel only can be done just removing the residual. Others say you should at least have the stock proportioning valve if you go front disc.
I finally found myself a 40 so I'm watching closely here as I'll likely follow your lead.
When you used the 60-series booster/master was it locking up the rear?
With the trooper booster/master does the rear lock up when you get on it hard?
I think you need a proportioning valve that focuses the brake effort into the front discs. For example...
https://forum.ih8mud.com/threads/brake-proportioning-valve-question.812137/
Reading through the threads I'm a bit confused... Some say you only need then proportioning valve if you go 4 wheel disc, that front wheel only can be done just removing the residual. Others say you should at least have the stock proportioning valve if you go front disc.
I finally found myself a 40 so I'm watching closely here as I'll likely follow your lead.
- Thread starter
- #151
Well finally got around to sorting out the brake issue for the front disc/rear drum set up. Basically the truck would slow down, but brake feel was very very soft, and eventually the truck would stop. Certainly worse than when we had front drum/rear drum original set up. I had taken everything off of a 60 series at the junkyard, so assumed nothing was missing. We never used the 60 master and booster as they were pretty much identical to the one currently in the Troopy.
After reading through several threads via the search, and thanks to @Honger lead above, I went back to the junkyard and spotted another 60 being parted out, and took a closer look at the booster/master set up.
This is what I saw
That was the elusive proportioning valve that was never given to me. I checked that 60 and it had front disc/rear drum, so the set up is the same as my now converted Troopy. So my guess was the dudes at the junkyard (they take everything off for you, as you're not allowed to pull stuff apart yourself) never gave me mine. Anyway, ended up picking that up.
Dousing it in diesel for some cleaning
And now finally installed. The brackets for the vale mounts right up to the two bolts already on the 4* booster on my Troopy. Buy two new short brake lines, connect them from the master to the proportioning vale, and the original lines are further bent slightly, to be routed now from the proportioning valve to the brakes
WOW! What difference that made. Now the truck stops superbly. Even when applying excessive pressure and the front dives before coming to a complete stop, the truck holds a straight line, there is none of that hopping or veering. Also the brake feel is excellent and firm, and best of all consistent.
I could not be happier. What a great and easy upgrade that is.
The weather has been cool lately, so have really been enjoying driving her around!
Till then.
After reading through several threads via the search, and thanks to @Honger lead above, I went back to the junkyard and spotted another 60 being parted out, and took a closer look at the booster/master set up.
This is what I saw
That was the elusive proportioning valve that was never given to me. I checked that 60 and it had front disc/rear drum, so the set up is the same as my now converted Troopy. So my guess was the dudes at the junkyard (they take everything off for you, as you're not allowed to pull stuff apart yourself) never gave me mine. Anyway, ended up picking that up.
Dousing it in diesel for some cleaning
And now finally installed. The brackets for the vale mounts right up to the two bolts already on the 4* booster on my Troopy. Buy two new short brake lines, connect them from the master to the proportioning vale, and the original lines are further bent slightly, to be routed now from the proportioning valve to the brakes
WOW! What difference that made. Now the truck stops superbly. Even when applying excessive pressure and the front dives before coming to a complete stop, the truck holds a straight line, there is none of that hopping or veering. Also the brake feel is excellent and firm, and best of all consistent.
I could not be happier. What a great and easy upgrade that is.
The weather has been cool lately, so have really been enjoying driving her around!
Till then.
- Thread starter
- #153
Thank you sir @cbmontgo
This is one AWESOME thread.
A) great cruiser. I would love to get my hands on even one of those "rusting in the junkyard" units!
B) great story: My
asked if I was jealous of the cruiser or the wife. I assured her it was cruiser. However, thank you to your wife for setting the example!!!!
C) great pics. The fact that you actually use the cruiser and take great pics in an environment that I will probably never wheel in is inspiring. Here I was afraid to scratch the paint on mine....
Thank you for the thread, and keep updating it with pics when you can!
A) great cruiser. I would love to get my hands on even one of those "rusting in the junkyard" units!
B) great story: My
asked if I was jealous of the cruiser or the wife. I assured her it was cruiser. However, thank you to your wife for setting the example!!!!C) great pics. The fact that you actually use the cruiser and take great pics in an environment that I will probably never wheel in is inspiring. Here I was afraid to scratch the paint on mine....
Thank you for the thread, and keep updating it with pics when you can!
WOW! What difference that made. Now the truck stops superbly. Even when applying excessive pressure and the front dives before coming to a complete stop, the truck holds a straight line, there is none of that hopping or veering. Also the brake feel is excellent and firm, and best of all consistent.
Glad you got this sorted... cause I'm shamelessly copying you on this mod. =) Also glad I was able to help a little... that way I'm not a total mooch.
Arabian Cruiser
Arabian Cruisers
Just read the entire thread. Came across it while searching boosters hahaha.
Subscribed . Am I too late ?
Subscribed . Am I too late ?
@boozewz thanks for the write-up! I'm sourcing all the necessary parts and in large part because of your recommendation I sourced a proportioning valve off a FJ60/FJ62 for the disc conversion.
-Geoff
-Geoff
- Thread starter
- #158
@jgeoffr excellent! I can't claim any credit though. I got ideas and suggestions from mud. What a great source of help this place is.
Post up pics of your rig. Its time we see her.
Post up pics of your rig. Its time we see her.
@jgeoffr , I heartily second this! We need a build thread...
We'll have to see... It's more of a disassembly thread right now. I haven't made enough progress... But man do I have the boxes of parts ready for when it goes back together. 
-Geoff
-Geoff