Builds "Scout" the 1977 FJ40

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Well, along the lines of... "spending too much time doing something I shouldn't worry so much about"...

I decided to take a moment to remove the air cleaner and valve cover in preparation for the valve stem seal replacement. That only took about 2 minutes so I decided to remove the rocker arm assembly too. It was disgusting! The pics below don't really do the sludge and caked on/dried oil any justice. I wonder how the rest of the inside of this engine looks.

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Before I removed it, I started it up with the valve cover off, just to make sure everything moved like it was supposed to. I took a few pics and removed the rocker arm assembly, placed it in a box and watched it puke about a quarter cup of oil all over. So I thought, if that thing is full of oil and it is that crusty, perhaps I should clean it. (hit the play button on some cleaning montage music)

I first took the valve cover out and put that purple super clean on the inside, scrubbed it and let it sit. It went from this....

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To this....

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I didn't worry about getting it completely spotless, I'd hate for someone to think I was obsessive compulsive or something like that. :rofl:

Then I flipped it over and wire wheeled the outside of it, cleaned it with carb cleaner, sprayed it with some engine primer and shot some aluminum color on it... and yes, I had to put the sticker on it too.
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It turned out really good and if you scroll up to the pictures of the hose clamps I replaced you'll see it was pretty damn ugly before.

And yes, it's clean enough to eat off, so I put it on the dining room table to take the pics. HA!
 
Then in the spirit of wasting even more time doing something that probably matters very little... I turned my attention to the rocker arm assembly. It had just finished puking the last of it's oil so I figured it was ready.

I thought about it for a bit and decided that the purple super clean was probably the best way to clean it, but that I needed to make sure it was completely dry and oiled up as soon as it was done being cleaned.

After I sprayed super clean on it and let it sit for a few minutes, I rinsed it, I used carb cleaner in the oil holes of the rocker arms and for lack of a better term the rocker arm bar. I then used compressed air to thoroughly blow out all of the oil holes in the rocker arms and the bar it all rides on. Words can't describe the amount of crusty crap that came out of those holes! I repeated that process over and over until all of the rocker arms moved freely and were free of the carboned up oil solids. Then I squirted oil in all of the holes and made sure the whole assembly was clean, free of water and oiled. If you haven't done this to your engine, I highly recommend it. Not only does it take a ton of time and make a huge mess but it also leaves the area you did this in smelling like 40 year old crusty engine oil. Your clothes end up smelling like an oil refinery and it takes 2 showers to get the black carbon out of your hair.

I doubt it did any good, but again the amount of crusty oil that came out of those oiling ports would shock you! I can't imagine any oil was actually flowing through them before. In some cases I could clearly see the holes were completely caked closed.

After shot....
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Wow, Dude, you don't hesitate to dive in and pull things apart - BALLS! :flipoff2:
 
After all of that fun, I started looking at the top of the head and wondered what those circular items were. Turns out they were simply freeze plugs filled with more of that 40 year old solid caked on oil. So out came a little flat headed screw driver and a shop vac. I made sure to use the two tools in unison so as to prevent any of that crusty stuff from making its way into the engine. It also looks like I'll have a little cleaning to do on each of the valve spring areas once I get the springs out of the way.

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Again, I recognize this doesn't do any good but I'm waiting for the valve stem seals so I figured I might as well keep busy doing something pointless.

I think it's probably normal to have this amount of caked on oil. I imagine the oil pan will be filled with all sorts of sludge too. It's next on my list as I see a tiny bit of oil seeping in-between the skid plate welded to the bottom of it. I hear that is a point of potential rust and then oil leaks... it's on my list to be replaced.

Until next time! Cheers!
 
Wow, Dude, you don't hesitate to dive in and pull things apart - BALLS! :flipoff2:
Thanks man, I was hesitant to dive in but it needs to be done and secondarily I figure if I get this thing to stop burning so much oil, my wife will be more interested in taking it for drives. Less stinky smoke = more driving it on the weekends.
 
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Very nice looking 40.
Thanks so much! I feel super lucky to have been in the right place at the right time to pick this up. I love projects like this so I'm feeling pretty happy with it all. I just found your build and I can't wait to read it! I for one enjoy seeing what others do with their Cruisers just about as much as I like working on mine.
 
I never really liked the way the Truck-Lite headlights looked on this vehicle so I replaced them with some Hella E-Codes. I have some pretty well liked LED bulbs coming to replace the halogen ones the Hella lamps came with. These new ones might not be quite as bright or offer as nice of a quality of light but they look 10x better in my opinion. The Truck-Lites are up for sale, PM me if you are interested.
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After reading @cbmontgo 's thread and enjoying the trip pics as much as the tech pics, I figured it's high time to post a pic of Scout doing what she's intended to do... explore places to drink beer and eat kick a$$ tacos with my wonderful wife. The tacos are great at Swift and Savory in downtown Duvall, WA and the Black Raven Trickster IPA is a PNW favorite.

A truly beautiful sight... sunshine, an American flag and a Land Cruiser. If it gets better than this, I'm not sure I can handle it.

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Another '77 Freeborn Red here...currently undergoing a frame off restoration. Nearing completion and will be posting the build soon. I like what you have done and you are doing it right. Congratulations on your rig.
 
I'm currently reading @Sea Knight 's amazingly well written account of his road trip in Uncle Meldon's 40 called Saving The Old Rustbucket. If you haven't read it yet, stop what you're doing and take the time to travel along with Lee on the best Land Cruiser road trip story ever written.

20 something pages in to Sea Knight's adventure I realize I didn't do my Land Cruiser procurement story any justice... there was a story after all. I just figured it wasn't worth sharing here. But after spending 4 hours reading Saving The Old Rustbucket, I think I'll document it... if for no other reason than I don't have any tech to write. The parts I ordered are still a day out.

I'm not the excellent wordsmith that Lee is, and if you hate this, don't read it, but it's the story of the first road trip in my FJ40 so it's vaguely relevant to this thread.

Part 1

I had just sold my prior project vehicle, a 1972 International Scout II which I completed 99% of a frame off restoration over a 3 year period... stopping short of completing the removable hard top. Mostly because I just simply didn't enjoy the rig after driving it a few times. It looked awesome and drove great, but it didn't "feel" like what I wanted in a project vehicle. It was big, loud and not super fun to ride in due to the fact that it was so loud and burned a copious amount of oil. Plus, I wasn't motivated enough to finish the top. Essentially, I built it to look cool but didn't really take in to account what I was really looking for... something for my wife and I to take on adventures. Lesson learned. I vow to not repeat those mistakes again.

Perusing through various Land Cruiser web sites while "working" one day, I noticed a rusty turd brown FJ40 on a very well known Land Cruiser restoration company's website. I figured what the hell, I'll call them and ask what was needed to get it back in to shape... maybe this is the rig for me. I was going to be in the Colorado area in the next few months anyhow so it might work out to pick this baby up on my way through. After a brief conversation I learned it needed some pretty serious rust repair. Having just completed the frame off restoration on my Scout II, which included welding nearly 40% new sheet metal in, I wasn't all that motivated to jump back in to the whole, grind, cut, weld, grind, day after day sort of work that I learned the turd brown FJ40 needed. I enjoy the mechanical repair side of things but I learned that I'm not all that keen on body work. So I asked him about the other one they had on their site, the green '77 FJ40. He said it was kind of an unusual story and that the vehicle wasn't in Colorado anymore, it was a hop skip and a jump away from me in Portland, Oregon!

As it turns out, the owner of the green 40 had been searching for a number of years for the "perfect" Land Cruiser to ship to this restoration company for a rebuild. He'd found this vehicle in Missouri, it was in really good condition, so he bought it and shipped it to Colorado to complete a restoration. The shop did a ton of cosmetic work including a partial repaint, some rust repair and a couple of mechanical repairs over 3 months it spent there. They then shipped it to Portland to the new owner's home having given it their seal of approval to be a "daily driver", which I'm quickly finding out, one person's idea of daily driver is vastly different than another's.
The very nice person at the restoration company proceeds to tell me that the green 40 owner didn't really run it past his wife before he bought the rig. Critical Fail #1. Also, he didn't realize that Portland Oregon still has a very strict smog test procedure so he couldn't license it without returning all of the smog equipment back to it's working condition. Critical Fail #2. In a matter of months, it's up for sale and that's where I find it.

I learned all I could from the nice gentleman at the restoration company and decided I'd call the current owner of the FJ40 to see what his thoughts were. I should share that the price listed was out of my budget but I felt it wouldn't hurt to learn more about the rig and why he was selling it. You never know right?

I left a message for him and received a call back within a few hours. The owner's story matched what the restoration company had told me in nearly identical detail. He shared all of the items that were replaced and what still needed to be done. It was half de-smogged and the engine smoked a little after it was warmed up. He wasn't that motivated to sell it and he wasn't willing to negotiate. I thanked him for his time, asked him to send me some pics and he did.

I spent the better part of the next day looking those pictures over and thinking, "this is the nicest FJ40 I've ever seen." I had looked at 3 local FJ40s for sale and while they were only a little less expensive they looked like they'd been run hard, put away wet and most of all they were cut up, rusted and needed serious attention to bring them up to the level that I was interested in. The In the Seattle area most people selling FJ40s take the price their vehicle is worth and double it regardless of condition. The crazy part is, they sometimes get what they're asking!

So I call the owner back the next day and let him know that "I'm interested in your rig but I don't have what you're asking. I don't want to di@k you around because I know you said you were firm on your price, but how exactly firm are you?" He must have been having a great day because he immediately came off the price enough that I could now justify it. I was stoked! I asked him to hold the vehicle for me until I could come down the next Friday and look it over. We agreed that I would send him a deposit to show my interest and set a date to make the trip. Now, I had to figure out how to get down there to look at it and possibly bring it home. I called my dad that night and asked him if he wanted to go on a road trip to check out an old Land Cruiser in Portland. Before I could even got the words out, he said "Sure!". All of the stars were aligning.

Knowing I was likely to pull the trigger on this thing if it was as nice as the pictures showed, I packed up tools and supplies I thought I'd need to make the trek back home. I figured preparing a little with some 2 way radios and a few other items may make the drive more enjoyable in an unknown 40 year old vehicle in 25 degree weather. That Friday at 6am sharp my dad rolls up to the house, I pack the tools in the back of his vehicle and we hit the freeway. It's pitch black still and I notice tiny little snow flakes begin to hit the windshield. The weather report called for snow around 1pm that day so we really needed to haul a$$ down there and back if we wanted to beat the snow. After an uneventful drive to Portland, we arrived a half hour early. To say I was excited to see this thing would be the understatement of the century. I was giddy!

The owner lived in an area of Portland high above the city in what can only be described as an old growth forest with a few houses thrown in for good measure. The drive to his home was up a steep two lane road through a forest filled with 100+ year old Douglas Fir and Western Red Cedar trees draped in heavy green moss with a dusting of snow here and there. This was the kind of drive you expect in a national park... not on the way to someone's home. We pulled in to the driveway around 9am, parked and was greeted by the owner who had a firm handshake and a trusting smile. He showed us to the garage, slid open the door and there it sat. The nicest FJ40 I've ever seen in person.

As I crawled underneath to inspect the undercarriage I had already made up my mind, this thing was going home with me. It was one of those decisions of the heart rather than the mind. The body and interior were perfect, but the undercarriage was surprisingly covered in 40 year old dirt, mud, oil, grease and general grime. I thought, that's strange, I thought this thing had just been at one of the most well known Land Cruiser restoration places for 3 months and they didn't even pressure wash the axles off? Whatever, I was going to buy this thing and that was that.

I spent a few minutes under it and visually inspected the important items. There were no fluid leaks of any kind and everything was where it should be. As advertised the springs were replaced with Old Man Emu 2" lift springs with Billstein shocks and brand new tires/wheels. The owner asked if I wanted to pull it out and start it up. After rolling it out he pulled the choke and cranked the starter a few times. With very little effort the 2F roared to life! I was so happy to hear that sound again.

Backing up a little, through my childhood, my family seemed to go through a large number of vehicles. Looking back, I can only say that my parents had rather "interesting" taste in cars. I remember a metallic green mid 70's Mercury Cougar, a Mercury Lynx station wagon with wood side paneling, a huge station wagon that looked like the one the Griswolds drove, an AMC Eagle, a Jeep Grand Wagoneer and a number of early 90's Pontiac Grand Prix and Grand Ams. With the exception of the Grand Wagoneer, non of those cars were memorable. But we also had a white 1984 FJ60 and an early 90's FJ62. Two vehicles which struck me as odd because they were so.... well, good! I'll never forget the sound those engines made as they dutifully carted my little brother and I to soccer practice, baseball games, and on family road trips. The exact sound this green FJ40 was making. It took me back to my childhood and the best part was, I could see my dad thinking the same thing.

After we let the FJ40 warm up a bit, we pushed the choke in and took it for a spin. Nothing of note, it drove pretty okay, lots of noise when I'd hit bumps and the engine didn't seem to idle smooth, run well or have much power... non of this mattered as I'd already made up my mind. We returned back to the owners home and I continued looking around the interior of the 40, opened the glove box and saw a temp gauge and a little silver stainless steel wire with two round mounting holes on each end. Due to it's proximity I realized it was a brand new replacement glove box door limit strap. I found it really odd that he had a new one of those in there and didn't just take the 3 minutes to replace the worn out one with wire strands sticking out all over. I would later find out that the owner of this FJ40 had either zero time, zero mechanical skills or zero interest in actually working on the Land Cruiser or maybe all three. Perhaps he just wanted to own one. It didn't matter, I had all three of those and this thing would be in my garage in a few hours, so it didn't really matter. Looking back from today's perspective, I'm happy he didn't touch this thing because we all know how POs can do more harm than good when they get a wrench in their hands.

10 minutes later, I handed him an envelope filled with too many crisp green hundred dollar bills and as he counted the money I loaded up the tools and supplies from my dad's rig to the FJ40. Another 10 minutes later and we were headed down the scenic road on the way home. It was getting colder by the minute and I'd asked my dad to lead the way since his car had navigation and we could quickly get back on the freeway and begin the trip home. I radioed to my dad that I needed to fill up with fuel and he radioed back that he found a station not far from us where we could fuel up before we hit the freeway.

As soon as I pulled up to the gas station I remembered that you don't pump your own fuel in Oregon.... they have people on staff to do that for you. I wondered, is this monkey going to scratch the paint, does he even know how to open the fuel door? I decided to get out and hand him the key to the gas door and eagle eye his fueling abilities. He walked up, grabbed the key and said, "Nice Land Cruiser, I don't think I've ever seen one this nice." He didn't call it a Jeep. NICE! I tipped him a few bucks and we were on our way. Dad in the lead with the navigation and me trying to keep up in a 40 year old vehicle I'd only driven a mile or so. In typical Dad fashion he made a u-turn and left me in the dust. Perhaps forgetting that my rig took a while to get up to speed. I tried the same u-turn maneuver and the car coming the other way, which was safely out of distance a moment before was suddenly on my rear bumper honking. They flew past me with a middle finger and I picked up the radio to call my dad. "Dad, slow down."

I roughly remember the route from the freeway to this guy's house as a pretty straight shot though an industrial area and up that winding two lane road with the beautiful trees. However, my dad was taking us back to the freeway using a different route. We'd lived in Portland as a kid for about 5 years and he had navigation, I figured, he knows where we're going. 20 minutes later and all of that time driving south on side streets and passing multiple freeway on ramps, I call him up on the radio. "Hey dad, where are we going? I don't remember coming this way." A crackle or two later and he says. "We're on the way to the freeway, I'm following the navigation system, maybe it has us going around some traffic or an accident or something." Fair enough.

Memories of a trip to San Diego 10 years ago start creeping in. My wife and I had just landed in San Diego to go to a wedding for my cousin Kari and her soon to be husband. We were going to the San Diego Zoo with my parents that day. My dad had rented a car and brought along his navigation system. He punched in the zoo and we were on our way. After about 40+ minutes in the car we arrive and explore the zoo for the day. When we're finished we pile in the car and take the 40+ minute drive back to the hotel we were all staying at. The next day my family attend the wedding and the really fun party afterward. The next day my wife and I decide to explore San Diego. We walk out of our hotel and up to this park a few minutes away. I see something interesting on a sign and I point it out to my wife. The sign has an arrow and it says San Diego Zoo 400 yards. I think to myself, there's no way we're that close, we just walked maybe 15 minutes at the most. I pull out my cell phone and check Google Maps. The San Diego Zoo is 400 yards away. WTF!!???

As it turns out, even though my dad is super smart, he has the tenancy to click the "avoid freeway" button on his navigation system. We're now driving for 40 minutes south through downtown Portland on side streets and I once again pull out my phone at a stop light, select my Waze app and push home. After a few seconds my phone gives me an overview of where we are and where we need to go. Once again, I soon realize my dad had hit the "avoid freeways" button on his nav. I radio him again. "Dad, did you hit the "avoid freeways" button on your navi?" Pause. Pause. he answers, "hmmmm, maybe that's what's happening." I radio back to follow me and I place my phone on the dash of my new 40 and pull ahead of him. We're on the freeway in about 3 minutes, sitting in traffic. It's 11:30 and the snow is going to start in a couple of hours. The last thing I want to do is drive this beautiful rig in a Seattle area snow storm. People in Seattle are known for being terrified of the white stuff. It only happens once or twice a year in our area and when it does the entire city comes to a standstill. Schools are closed, grocery stores are emptied it's pandemonium. After the inch or two of snow melts the hundreds of cars that people abandon on the freeway are still there. No joke, people get out of their car and leave them right there on the freeway. Where they go is anyone's guess but they park their cars on the freeway and walk home. Being from Alaska originally, I find this to be one of the funniest things I've ever seen.

We're motoring along up I-5 around noon just past Longview, the rain/snow mix starts. I slow down from 60mph to 50mph and get in the far right lane. I turn on the wipers and the rubber blade pieces are evidently not interested in cooperating. 80% of them stay glued to the windshield, encapsulated in ice. My dad and I are in for a long drive.

To be continued...
 
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I received the valve stem seals from SOR yesterday and installed them. It's a tedious job but on a scale of 1-10 I give it a 3, it's pretty damn easy. I'll do a more thorough write up, I took pics and by the last one I was pretty quick at it. The good news is I think it helped alleviate much if not all of the oil burning when accelerating away from a stop light after idling for a while with a hot engine. So good news there because the less smoke and smells that come out of Scout the more my wife wants to take it on adventures.

This post is about the difference it made by cleaning up the rocker arm shaft from post #22. After buttoning up the top end and idling the 2F with the valve cover off for a bit, I noticed a stark difference compared to when I idled it with the valve cover off before I cleaned the rocker arm shaft. If you reread post #22 you'll see what I mean. I spent some serious time cleaning the rocker arm shaft, cleaning out all of the little oil holes in the rocker arms and the shaft and essentially de-gunking the entire assembly. It took some time and it was a dirty task that involved lots of compressed air and carb cleaner. I think this extra step may have really helped.

As you can see below....

This picture is taken about 5 seconds after I shut down the engine, before cleaning the rocker arm assembly oil holes.
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This picture is taken after I cleaned them out but while it was running... so not a direct comparison, but keep reading.
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I'm focused on those oil holes in the rocker arms for a reason. I remember when I initially watched the rocker arms operating at idle before I cleaned them and I thought, "I wonder how they get oiled." If you look in that top picture, there's no oil coming out of those holes and only a small amount on the top of the valve spring. Now, with the oil holes cleaned out, there's a constant flow of oil coming out of those holes and on the passenger side of the engine if you watch the rocker arms moving you'll see oil pouring out all of the oil holes making sure the whole assembly is lubricated. After the oil drains out of the shaft and rocker arms and on to the top of the head, the oil drains down the holes for the push rods and I'm guessing drips on the cam lobes and lifters. Before I cleaned these, there was no significant oil draining down those push rod holes.

Proof is in the pictures... again 5 seconds after I shut the engine down BEFORE they were cleaned. Nearly no oil on the top of that head.

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I'm thinking that other 2F rocker arm assemblies are in the same condition that mine was. So it might be a good idea to take a look at yours as it idles and see if there is adequate oil being distributed. In mine there was essentially none and my engine only has slightly less than 100k on the odometer.

I'm certain someone with more experience with these engines can either verify or debunk what I've just mentioned. However, with the minimal amount of effort it took to clean all of these oil holes out, I'm certainly glad I did it.

I'm also really glad I replaced my valve seals. See below.

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The one on the bottom is clearly the old valve stem seal. The hole is all hogged out and the rubber seal portion was hard and brittle. the old seal was making no contact with the valve stem... so oil was dripping down the stem at idle and then being sucked in to the cylinder past the valve stem seal as I accelerated away from the stop light creating the fantastic "stay off my a$$" cloud of smoke. More on the steps I took to replace those in a future post.
 
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Valve Stem Seal Replacement -

(I'm sure I'm not the first person to share this info here, but for posterity I'll record it regardless.)

After I removed the air cleaner assembly, the valve cover and the rocker arm assembly I start by pulling the spark plug on the cylinder I'm working on and installing this compressed air valve holder I found on Amazon for about $10. I pressurize the cylinder to a constant 90psi.

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Then I installed the Valve Spring Compressor tool I found on Amazon for $15. I found that if I made sure the lowest spring arm of the tool was at the lowest possible point on the spring, it made the job of removing and installing the keepers ten times easier.
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After fully compressing the spring, I removed the keepers.
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Here's what the spring looks like after I removed it.
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Then, I removed the valve spring seal by prying it off with a flat head screw driver. It was on there pretty good.
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Next up I remove the valve spring seat.
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I used a small flat head screw driver and shop vac to scrape out the crusted 40 year old oil. Then I replaced the valve spring seat.

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I put the new seal in a small cup with some motor oil to lube the thing up before pressing it over the ridges for the valve keepers and on to the valve stem.

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I used a 15MM 12 point socket and small hammer to press the seal down on to the head.

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After a few taps in to place, it's on.

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I then put the spring back over the valve stem and reinstall the keepers and move on to the next valve on that same cylinder.

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All told the job took me 2.5 hours. I did the first two cylinders to get the hang of it because they're easy to reach and then started on #6 and worked my way forward.

After I was finished and put the rocker arm assembly back on I started it up, got the engine nice and warm and then revved it up a few times... no more blue smoke clouds from the tail pipe. I've yet to drive it because I have some other things I'm doing at the same time but once I do I'll report back on how convinced I am that this fixed the smoking issue I had.
 
I am enjoying this process immensely - keep it coming :clap:
 
I am enjoying this process immensely - keep it coming :clap:

Thanks so much LasCrucer! I really appreciate all of the knowledge shared here thus far, so I'm hoping to add to it if possible.

After reading a good chunk of Sea Knight's story, I've ordered up a clutch slave, master and hose. Mine are leaking and as crusty as they get. So that will be next. My wife and I plan on taking this thing for a 500 mile road trip in a couple of weeks and I want to make sure I don't end up like Lee in Pueblo.
 

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