Builds South Texas 97 - New to me (2 Viewers)

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From Watson Lake drove to Haines Junction. Easy drive but sparse gas stations along the way, especially when I’m getting on 10-11,mpg. I put 5 gallon in about 20 miles before Teslin, and the filled up the tank there and refilled my 5 gal container.

Very hard to start this morning- took about 10 minutes to get it idling at all, and even so is running quite rough.
If I keep the revs up around 23-2500 it more or less runs ok. But no power on the hills. Even on flat ground it is not accelerating nicely and I get lots of pinging or small backfires

My plan now is to get as far as Anchorage. I feel it would be not responsible to get stuck in Colfoot or in Deadhorse, if I cannot get the truck started or running smoothly.
 
So far I’ve replaced the TREs, added Delta Radius Arms and replaced the rubber steering coupler. I’ve made a 3/4 turn of the adjustment screw, and it’s at full stop. Only untouched item is the box. It’s bone dry so I’ve had no reason tk mess with it. My rig is almost 96% full restoration and running 33” on a 2.5” OME. No wheeling- Daily Driver. Tandem Off-road near me said they could rebuild for about $400. I was shopping online last night for an OEM @ $1800. Researching the Redheads(?) now.


Edit. Photos
400 is what the Adco shop in Houston charged me 5 years ago. So it could be a good deal.
 
From Watson Lake drove to Haines Junction. Easy drive but sparse gas stations along the way, especially when I’m getting on 10-11,mpg. I put 5 gallon in about 20 miles before Teslin, and the filled up the tank there and refilled my 5 gal container.

Very hard to start this morning- took about 10 minutes to get it idling at all, and even so is running quite rough.
If I keep the revs up around 23-2500 it more or less runs ok. But no power on the hills. Even on flat ground it is not accelerating nicely and I get lots of pinging or small backfires

My plan now is to get as far as Anchorage. I feel it would be not responsible to get stuck in Colfoot or in Deadhorse, if I cannot get the truck started or running smoothly.
You could possibly stop by Cruisers Only in Wasilla and have Mark Whatley assess your problem. He has a wealth of Cruiser knowledge from owning and working on countless trucks over the years. I’d give a call in advance if you decide to go that route. Wasilla is basically on the way to Anchorage.
I love Haines Junction area. Hope it’s fun for you. From there to Tok is a long haul. Beware the frost heaves on either side of the border. Just need to slow down a bit…
 
Excellent advice, I will call them today. My plan for the day is Tok Junction, we will see how it goes.
Indeed the frost heaves make the truck wander quite a bit. First time it happened it was pretty scary, although no oncoming traffic fortunately.
This area is truly spectacular. Still so much snow on the mountains- perfect!
 
Excellent advice, I will call them today. My plan for the day is Tok Junction, we will see how it goes.
Indeed the frost heaves make the truck wander quite a bit. First time it happened it was pretty scary, although no oncoming traffic fortunately.
This area is truly spectacular. Still so much snow on the mountains- perfect!
I believe there's also a shop in Tok that's fairly competent with general auto mechanics. They get a lot of Alcan highway repair work.
BTW, an alternative to the Dalton if you are sure about bailing on that would be: From Wasilla drive Hatcher Pass over to the Parks Highway, then Denali highway over to Richardson highway before heading south. Hatcher and Denali highway are all gravel with fantastic mountain scenery, far more interesting than Dalton, when the weather is good. And BTW, forecast is looking promising in the next few days. It will finally warm up!
 
Made it to Tok, the customs folks were very complimentary about the truck.
After I stopped at Tok decided to check out a local mechanic, nice guy but he didn’t have much new information for me except perhaps the coil was old and tired. Truck running very rough and terrible to start. On the way back from the mechanic noticed the voltage was 12.5, anytime driving should be at 14.5.

That’s it! I called it at Tok. No further abuse of an FJ40.

Now to get it back to Texas. Tok is about 190 miles from Fairbanks, so looked around and found a truck and car carrier in the North Pole, a suburb of Fairbanks. To get from Tok to Fairbanks I looked at a bus, uber,
IMG_5947.jpeg
and hiring a local to drive me there. Turned out the best way to pick up a U-Haul truck in Tok and one way to the U-Haul in North Pole. Around a three hour drive or so, mostly excellent roads the whole way. Got to the dealer, and the U-Haul website was down, AND my credit card was declined. Made some phone calls, and after 3 hours had a truck and car carrier on my way back to Tok for the night. The land of the midnight sun is true, made it back by 9:30 still daylight.

Next morning used an old school trick of using the starter in first gear to get the truck loaded on the car carrier. Probably killed my battery and perhaps the starter, but it worked a charm.

Tied everything down with some extra ratchet straps in addition to the normal tie downs, and headed back to Haines Junction for the first night. The road is very rough so took it slow with the loaded trailer and stopped every hour or so to check the tie downs.

Had some freezing rain , snow on my windshield, on the way after Beaver Creek. Felt sorry for the motorcycle riders, and perhaps half a dozen bike riders.

The strange feeling with the U-Haul truck is I can see the outside edge of the trailer, but not the FJ40 itself.

Stopped at Haines Junction again for the night and came across a guy going to Alaska with an old GMC he wants to restore
IMG_5951.jpeg

I’ve started thinking about what needs to be done.
Clean everything first, including the K&N air filter and reoil it.
Check/ replace alternator, it is a reman from Wilson. There is a local alternator shop that should be able to test it, but a suitable alternator is not that expensive.
Check tappet/valve clearances.
Compression test, and perhaps a leak down test.
Verify timing with timing light.
Replace fuel filter
At the risk of throwing the parts canon at it, new plugs, wires, dist cap, rotor, coil. Even if something else is wrong, I never replaced the plug leads or coil when I got the truck.
Reset the sniper by running the wizard.

Thoughts and suggestions welcomed from the experts
 
Made it to Tok, the customs folks were very complimentary about the truck.
After I stopped at Tok decided to check out a local mechanic, nice guy but he didn’t have much new information for me except perhaps the coil was old and tired. Truck running very rough and terrible to start. On the way back from the mechanic noticed the voltage was 12.5, anytime driving should be at 14.5.

That’s it! I called it at Tok. No further abuse of an FJ40.

Now to get it back to Texas. Tok is about 190 miles from Fairbanks, so looked around and found a truck and car carrier in the North Pole, a suburb of Fairbanks. To get from Tok to Fairbanks I looked at a bus, uber, View attachment 3927105and hiring a local to drive me there. Turned out the best way to pick up a U-Haul truck in Tok and one way to the U-Haul in North Pole. Around a three hour drive or so, mostly excellent roads the whole way. Got to the dealer, and the U-Haul website was down, AND my credit card was declined. Made some phone calls, and after 3 hours had a truck and car carrier on my way back to Tok for the night. The land of the midnight sun is true, made it back by 9:30 still daylight.

Next morning used an old school trick of using the starter in first gear to get the truck loaded on the car carrier. Probably killed my battery and perhaps the starter, but it worked a charm.

Tied everything down with some extra ratchet straps in addition to the normal tie downs, and headed back to Haines Junction for the first night. The road is very rough so took it slow with the loaded trailer and stopped every hour or so to check the tie downs.

Had some freezing rain , snow on my windshield, on the way after Beaver Creek. Felt sorry for the motorcycle riders, and perhaps half a dozen bike riders.

The strange feeling with the U-Haul truck is I can see the outside edge of the trailer, but not the FJ40 itself.

Stopped at Haines Junction again for the night and came across a guy going to Alaska with an old GMC he wants to restore
View attachment 3927106
I’ve started thinking about what needs to be done.
Clean everything first, including the K&N air filter and reoil it.
Check/ replace alternator, it is a reman from Wilson. There is a local alternator shop that should be able to test it, but a suitable alternator is not that expensive.
Check tappet/valve clearances.
Compression test, and perhaps a leak down test.
Verify timing with timing light.
Replace fuel filter
At the risk of throwing the parts canon at it, new plugs, wires, dist cap, rotor, coil. Even if something else is wrong, I never replaced the plug leads or coil when I got the truck.
Reset the sniper by running the wizard.

Thoughts and suggestions welcomed from the experts
Based on what I see of those plugs, you're running very lean. Plugs are burning white which means hot and lean. They should be light tan.
When they are that hot, the resistance to firing goes way up and if your plug wires are questionable, then they may start arcing out and failing due to high resistance.

Since I now know you're running a Sniper fuel injection system, you need to make sure it automatically adjusts for elevation. As you go up in the mountains, the air gets much thinner and the fuel should decrease in order to maintain a proper air/fuel ratio so I would have expected your plugs to be black with soot from running rich. Power goes way down because total fuel consumption is down. At sea level your ratios are easy to deal with and you have little elevation changes. Running that far with those elevation changes, you have made things very hot.

Then having a weak alternator not putting out the power needed and weak plug wires with too much resistance makes for a "perfect storm" of consequences.

Stay Safe!
 
Based on what I see of those plugs, you're running very lean. Plugs are burning white which means hot and lean. They should be light tan.
When they are that hot, the resistance to firing goes way up and if your plug wires are questionable, then they may start arcing out and failing due to high resistance.

Since I now know you're running a Sniper fuel injection system, you need to make sure it automatically adjusts for elevation. As you go up in the mountains, the air gets much thinner and the fuel should decrease in order to maintain a proper air/fuel ratio so I would have expected your plugs to be black with soot from running rich. Power goes way down because total fuel consumption is down. At sea level your ratios are easy to deal with and you have little elevation changes. Running that far with those elevation changes, you have made things very hot.

Then having a weak alternator not putting out the power needed and weak plug wires with too much resistance makes for a "perfect storm" of consequences.

Stay Safe!
He may have been at high elevation if driving through Colorado but beyond into Canada and Alaska elevations are moderate, typically 2,000 ft. or less.
 
Thanks @BILT4ME , I think this is exactly the issue. I replace the plugs,dist cap and rotor but never changed the plug wires or coil. This would also explain the hesitation at speed, one plug not firing properly perhaps, and the problem getting worse over the 2 weeks I was on the road. I was blaming the sniper, but I think it was doing its damnest to keep the truck running under less than ideal circumstances.
I will add checking the vacuum advance to the list above.
The alternator was consistently charging at 14.5, but it is a reman, so perhaps it is time to replace rather than rebuild.
Cannot complain, have done just over 3,700 miles up through the Rockies. And ended up about 700 miles short of my goal of Deadhorse.

Lessons learned, and lots of amazing scenery and good people along the way.

Returning in the U-Haul towing a car carrier with the FJ40 on board, I am actually pretty impressed by how the 40 performed.
Came across a LeTourneau road train in Whitehorse. The wheels are about 10 ft tall, and it’s a diesel/electric. There are some YouTube videos about them. Never thought I would see one in real life. Amazing
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IMG_5969.jpeg
 
BTW, Dalton Highway is now closed due to flooding/damaged culvert and is expected to remain that way for a couple days...
 
Well, not much more to report, they let me back in to the US, and I should be in Colorado Springs tomorrow night. Decided to travel down the front range. Billings, MT, Douglas WY, and then Colorado Springs, Amarillo, and perhaps Abilene

I did stop at a YouTube guy I watch, Engels Coach shop that was a treat.
Hopefully I can stop at redline Landcruiser in Colorado Springs on Thursday morning @RLMS after 3700 miles it would be nice to not have to downshift quite as much on the hills.
 
I got to the Redline shop on Wednesday afternoon and the guys were very generous with their time. They are doing some very cool things, and have more coming. We spent 45 minutes with the hood up, and looking at almost all the things I have done so far, some excellent feedback that I will be taking on board.

I think they were impressed I made it 3700 miles.

Got back to Houston Saturday afternoon

The work on the ‘40 continued on my other thread.

Post in thread '76 FJ40 in South Texas'
Builds - 76 FJ40 in South Texas - https://forum.ih8mud.com/threads/76-fj40-in-south-texas.1301398/post-15978956

Thanks for watching as they say…
 
Well, the end of an era as they says, sold the 97 Series 80 to a very nice guy in North Carolina. For a small fee drove it up to him in NC. Nice two day drive up from Texas. I stuck to 60-65 and was getting a measured 18 mpg. Not bad at all. Temperatures stayed around 190 but would creep up to 198 on the hills. Truck behaved very well. I will let the buyer take it from here.
IMG_6478.webp
 
What's next?
 
Ah, what's next is the big question.
As you may know, I have a 76 FJ40 that has an engine with very low compression, so my next project is to get that engine out and to an engine rebuild shop - that is targeted for mid October, as I am out for the next 3 weeks on vacation visiting family.
After that, we will see - I had in the back of my mind that if no one wanted the 97 Series 80, to do an engine/transmission swap to a Denali or similar 10 speed 4x4.
Will see what happens towards the end of this year.
 
Yeah but that sets you at only one project vehicle! We've come to expect more from you!
 
Thanks, @robchapa , it's always a challenge to keep going. Start with something simple and work your way along from there.
The wisdom on the forum is
1/will it kill me, (brakes, brake lines, fuel lines, alignment (steering wobble) etc)
2/will it make it not as enjoyable to run (hard starting (vacuum lines, lights, a/c, vibrations, etc etc)
3/fun, nice things - improved radio, nice rims/tires, etc etc.
 

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