The Iron Sheika - 1989 FJ62 Build Thread **Heart Transplant Time**

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Joined
Mar 30, 2015
Threads
4
Messages
25
Location
Olive Branch, Mississippi
I rescued this 1989 FJ62 last year while living in Dubai. It was a US vehicle originally, having spent the majority of her life in Arizona (so almost 100% rust free). I bought her from an Iraqi gentleman who had purchased her and a 1985 FJ60 via an online salvage auction, and used them just to fill up a shipping container he used to import a beautiful Porsche 550 as a restoration project. The cruisers just sat deteriorating in front of his shop for over a year before I happened to drive by and notice them. After a bit of negotiating typical of the region, she was mine!

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Other than the lack of rust, the vehicle was not in great shape. The interior was original but shot, and a year in the Dubai heat and sun had taken a toll. It cranked, but idled terribly. The lights didn’t work, and it sat on bald tires with bent rims. I slowly drove it to a shop that I trusted, and asked them to evaluate it top to bottom (and hoped for the best). After their initial assessment, I asked them to do everything required to make it a reliable daily driver. They did a great job, and I happily drove it for a few months, doing various upgrade projects along the way.

I moved back to the USA last summer, and had her shipped back to me. We were reunited last fall after a long shipping process, and she is not splitting time with another vehicle for daily driving duties. I’m now at a crossroads in this project, so I’m trying to decide where to focus my attention next. I would really love some forum input! Oh, and here's how she looks now:

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Here’s what has been done so far:


  • Full mechanic inspection of vehicle

  • Replaced front brake pads and rear brake shoes

  • Tie rod ends replaced

  • Stabilizer links and bushings replaced

  • Fuel pump replaced

  • Leaf spring bushings replaced (24)

  • Suspension bushings replaced (4)

  • Front differential bushings replaced (4)

  • Fuel pump strainer and fuel strainer grommet replaced

  • Ventilation hose replaced

  • Fuel filter replaced

  • Spark plugs and wires replaced

  • Vacuum valve replaced

  • A/C system re-gassed

  • Gas tank was dropped and cleaned out thoroughly, and fuel lines were flushed

  • Window film removed and re-tinted with 3M film

  • Interior carpet replaced

  • All the interior upholstery (seats, door panels) replaced with leather

  • New headliner installed

  • Steering wheel and shift knob covered in matching leather

  • Every light bulb on the vehicle (except for the headlights) with LED’s

  • Broken light covers replaced with new or NOS replacements

  • Installed HID headlights and upgraded the wiring harness

  • Rubber-coated the front grill and rear vents

  • Installed a Roadrunner Slimline II roof rack, with the hi-lift jack attachment (with jack)

  • Installed Roadrunner cargo compartment locking drawers. I re-made the removable side wings to fit perfectly (they were originally for a 100 series), and installed rear speakers in them.

  • Replaced the stereo with a Pioneer NEX-4100.

  • Added a backup camera (and bought a forward camera as well, which I will install once I change out the front bumper)

  • Replaced the old cracked dash pad with a brand new OEM replacement (this was a bit of a splurge, but it is really key to the interior looking and feeling new)

  • Replaced the tires & rims with black Mickey Thompson rims and 33” Yokohama tires, and added spacers to get the fit I wanted.

  • Replaced cracked/missing interior and exterior plastic pieces

  • Replaced missing exterior chrome trim pieces
Here’s the current status of issues and items/projects on my shortlist for next steps:

  • Suspension upgrade. All the love for the OME kits is pushing me heavily in that direction, as the current setup provides lots of, um, feedback. I just want to make sure my ride height does not change much. I do not believe the current suspension is stock—I am running 33 inch tires with no issues as all, and it appears to sit higher than the stock vehicles I typically see.

  • Bumpers/winch. My original chrome bumpers, front and back, are pretty scuffed up and do not necessarily suit the blacked out nature of the rest of the vehicle. I’m shopping for black aftermarket bumpers/brush guards. The ARB front bumper would be easiest I think, but I do not necessarily love the look of the tubing sections that surround the headlights.

  • Power windows. The power windows work, but slowly, and the passenger window has to be helped back up. I bought the relays, etc. to do the upgrade detailed on this forum, and will do this whenever I find some time.

  • Transmission. Sometimes it shifts into reverse fine, but seems to slip out of gear after I reverse for a short distance. Shifting into drive and back into reverse resolves the problem. What could be going on here? Also, certain grade angles (long, steady, mild inclines) seem to befuddle the transmission—it won’t downshift, so I’m stuck poking along slowly.

  • Engine. The 3FE is what it is, and I appreciate the reliability. I’d love to do a Vortec or diesel swap eventually. The only real concern I have in the short term is the occasional really rough idle after being stopped for a few minutes (like in a driver through line). It has never actually cut out completely, but it seems really close to doing so.

  • Brakes. She drinks brake fluid—I have to top off the fluid every week or two.

  • Console. I would like to add a locking steel center console (Tuffy Box).

  • Camping accessories. I want to add the Roadrunner rooftop tent and side awning.
Again, your thoughts on what to do to it next would be most appreciated. And the goal of the build is to have a fun almost-daily driver (very short commute) and a capable camping/trail rig. Thank you!
 
That interior is fantastic
 
  • Suspension upgrade. All the love for the OME kits is pushing me heavily in that direction, as the current setup provides lots of, um, feedback. I just want to make sure my ride height does not change much. I do not believe the current suspension is stock—I am running 33 inch tires with no issues as all, and it appears to sit higher than the stock vehicles I typically see.
May have had add-a-leafs added or some other mods. Check your shocks for age/leaks. Post up a closeup photo and we can chime in.

  • Power windows. The power windows work, but slowly, and the passenger window has to be helped back up. I bought the relays, etc. to do the upgrade detailed on this forum, and will do this whenever I find some time.

    Clean the tracks, lube the guts in the door (remove nasty/hard old grease), and read up in the forum.

  • Transmission. Sometimes it shifts into reverse fine, but seems to slip out of gear after I reverse for a short distance. Shifting into drive and back into reverse resolves the problem. What could be going on here? Also, certain grade angles (long, steady, mild inclines) seem to befuddle the transmission—it won’t downshift, so I’m stuck poking along slowly.

    Check the kickdown cable adjustment, fluid level, and maybe change the fluid if it's not pink and clean. I often manually downshift before the need, to be nicer to my transmission.

  • Engine. The 3FE is what it is, and I appreciate the reliability. I’d love to do a Vortec or diesel swap eventually. The only real concern I have in the short term is the occasional really rough idle after being stopped for a few minutes (like in a driver through line). It has never actually cut out completely, but it seems really close to doing so.

  • Check for vacuum leaks (loose fittings, cracks) in all the intake tubing, see if the exhaust smells rich during these stumbling periods - running rich?

  • Brakes. She drinks brake fluid—I have to top off the fluid every week or two.

  • If the system is not leaking to the outside world, your brake booster could be filling up - pull the master away from the booster and see if it's all wet on the backside.
 
I'll echo the sentiment. Interior is sweet. After extensive research and trying a set of subaru seats myself, nothing looks as good as an updated stock interior. I'm about to go through my rear seat, did you refoam the rear or just new upholstery?
 
Love the interior. I'd like to see some photos of the front seats too. @SteveH gave you a good rundown on your maintenance issues. Work on those next.

Now, if you really want to transform your driving experience, drop a 5-speed in and start driving. It's a splurge too, but I don't think you'll regret it.
 
Wow, super feedback, you guys are awesome. I regret being a lazy lurker as long as I have! @SteveH, those suggestions are exactly what I was hoping for. I'll do what you suggested for each item and see what happens!

Regarding the seats, they did add new foam across the board, and they are all really comfortable now. I will definitely take some better interior photos to share, as I was really pleased with how they turned out. It wasn't all perfect though-- I had asked them to remake/recover the vinyl on the dash also, which was really cracked and brittle. What they provided was a tailored-to-perfection cloth cover that they secured with Velcro, which looked like hot garbage. It's a common way to address cracked dashboards there, which happen frequently due to the extreme heat/sun. Now that I think about it, I should just be glad it wasn't some sort of fur or deep shag carpet which is pretty normal to see.

Oh, and the manual transmission is definitely on my radar! I actually got a quotation before I shipped it back to the states from a local shop that said they could add a manual Toyota transmission and a low mileage Lexus V8 for about $4000 USD. That would have made the export/import process even more complicated than it was, otherwise I would have strongly considered it. :)
 
Beautiful FJ62! I love the white w/black trim look you have going.

I can't recommend the Vortec swap enough. I loved the reliable old 3FE, but when my transmission (A440) went at around 250,000 miles, instead of getting it rebuilt/replaced or spending $2500+ to swap in a manual, I decided to swap in a 5.3L and the associated 4L60E transmission. You can read about my swap via the link in my signature block, and there are dozens of better threads that detail the process - and the commitment - ad nauseum.

Beyond the Vortec swap I highly recommend the OME upgrade. I did it as a byproduct of the swap (the swap took on a life of its own) and haven't looked back. I did a light duty front and a medium rear, but in retrospect I would have done Medium all around.

I have designed a drawer system for camping that I'm going to get started on Saturday; stay tuned for that thread. My system will accommodate a fridge/freezer, a camp kitchen, dry storage, and a sleeping platform; I took the best of everything that has inspired me on this forum and hopefully will combine that into something that best fits my needs (National Park camping vice deep off-road overlanding - for now).

I hope this helps a little, and I wish you the best! Keep us posted on where you go next...
 
I can't believe it has been so long since I originally posted this thread! Over the past 3 years, I continued to do small upgrades here and there:
  • Custom front bumper
  • Warn winch (which I rebuilt-- fun project!)
  • Tuffy center console with LED switch panel
  • Hood decal
  • LED lights
  • Dual battery setup
  • Full desmog
  • Mean green alternator
I also chased an overheating issue that eventually took a complete replacement of the cooling system to resolve (new radiator, hoses, thermostat, cooling fan, belts, etc.).

With all the above projects done, she has been a great daily driver over the last couple of years. However, a few weeks ago the unthinkable (but inevitable) happened. With around 220k on the odometer, the engine failed catastrophically. Subtle knocks, quickly followed by loud knocks, and then a final groan leading to silence...

I went through all of the options. Should I walk away? Rebuild the engine? Do a swap? After a couple weeks of thinking it over, I settled on a path forward that I'm very excited about. She is currently at a professional garage that I trust, with the following work scheduled to be performed over the next 5 weeks:
  • Installation of a newly remanufactured and warrantied 3FE
  • Conversion to a 5 speed (brand new H55f)
  • Knuckle rebuilds all around
  • Brake system rebuilds all around
  • New shocks (going with KYB's based on recommendation and partly due to color scheme matching :) )
This is obviously a big job, but when I compared the cost of doing this (and what I would end up with) with what sort of vehicle I could get for the same amount, it was a very easy decision. Now, I'm consoling myself during this long waiting period by looking at all of the project pictures on this site. I'll be sure to post pictures and performance feedback as soon as the work is done and she's back in my possession! In the meantime, here are a few pics I don't think I've posted before. :)

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