Builds The Ole’ Green Mile-77’ FJ55 (1 Viewer)

[southerncruiser62]

While still letting the kids come up with a name for this build/very mild resto, I wanted to give it its own place for update 77 FJ55. Formerly Frees old truck, I wanted to get back in a 55. Though we’ve enjoyed the last year there have been several things I’ve wanted to redo/upgrade in it.

first few things were to clean up rear seat and redo front grill.

 

[southerncruiser62]

I’ll bring in my posts from the front end rebuild and new brakes. After wrapping that up I wanted to get started on the old heat reactor replacement. I found a couple leaks while peaking around and having done the 3FE manifold swap on the 79 55 I had, I thought this was a great upgrade for this truck as well along with desmog.

I started this morning tearing things down and removing air pump as I felt it was shot, and of course upon removing found pieces sitting on the bottom of pump. More surprising was the leak I thought I found wasn’t nearly the bigger leak, back side of heat reactor had at one time been repaired and cracked again. I am going to separate everything this week and start cleaning things up for reassembly. Have a few things to get 3FEs blocked-off and ready for remainder of new exhaust.

I’ll update more as work progress, till then a few pics

 

[southerncruiser62]

Front end rebuild and brakes.


I had been meaning to get front end rebuilt for past several months and really before Christmas party. Well tackled this past Thursday and wrapped up new calipers and pads this morning.

As you’ll see always good to check pads on some sort of routine. Hadn’t heard anything unusual and hubs weren’t terribly hot. Stuck piston, broken pad.

 

[Ol Yeller]

I’ll bring in my posts from the front end rebuild and new brakes. After wrapping that up I wanted to get started on the old heat reactor replacement. I found a couple leaks while peaking around and having done the 3FE manifold swap on the 79 55 I had, I thought this was a great upgrade for this truck as well along with desmog.

I started this morning tearing things down and removing air pump as I felt it was shot, and of course upon removing found pieces sitting on the bottom of pump. More surprising was the leak I thought I found wasn’t nearly the bigger leak, back side of heat reactor had at one time been repaired and cracked again. I am going to separate everything this week and start cleaning things up for reassembly. Have a few things to get 3FEs blocked-off and ready for remainder of new exhaust.

I’ll update more as work progress, till then a few pics

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So going with newer manifold?

Will be watching, great project!

 

[roadstr6]

Looking forward to more on the 3FE manifold change-over. My 55 has what looks like '78 FJ40 manifolds. My heat reactor bushings are leaking. I was thinking about removing the flap and blocking off the holes. Curious to see if 3FE might be a better option for me.

 

[southerncruiser62]

Here is the link to previous thread created on the 79’ 55 3FE upgrade I did.

Head Gasket Replacement-FJ55

Alright so some of you have probably been wondering why I haven't been doing keeping up on the board recently, well it's because for whatever reason I am bound and determined to make something of this here 55. I know I had mentioned that in the past I had been having cooling problems with the...

forum.ih8mud.com

 

[PabloCruise]

Broken pad?!? Ouch!

 

[wngrog]

Love the fan on the front of the engine. 3rd one I’ve seen in a month

 

[jfz80]

That was one of my favorite parts of that pig and it kicked on and off like clockwork after a drive.

Grill looks 100x better too Greg. Nice work all around.

 

[southerncruiser62]

Minor update as I’ve been helping a neighbor with welding rear bumper project. Got manifold clearance’d for 3FEs to slide in. Plan to clearance the flanges tomorrow.

 

[southerncruiser62]

Update, finally got around to doing more research on how I previously clearanced the 3FEs on the 79 I had. After figuring out what I did I got to work this evening. I recalled taking a cutoff wheel on dremel and marking depth needed to clearance. Then cut line in for material needing removed. Because I want things clean I then ground down remaining material to keep things looking factory. Little clean up needed and some final measurements with calipers to ensure flush but here’s the one side. Hoping to knock out other side tomorrow

 

[southerncruiser62]

Got the other side clearanced tonight. After doing the one side this evening was much closer and cleaner. Took a pic so one could see how I cut in then ground down remaining material. This will also give the ability to make up a little variance with washer. Hopefully this is helpful for others.

Now I’m trying to figure out if I go remflex gasket or stock. Remflex will require longer bolts and studs but likely eliminate leaks later. Either way I’m hoping to get it all reinstalled by the weekend.

 

[southerncruiser62]

Well a few parts showed up earlier than expected. Thanks to Fred Anderson Toyota (Pedro) here in Charleston for his/their continued support. I tried to include all part numbers for those looking to do this in future. I am obviously going remflex just to be safe. Also went with 090-099 Forman drain plug for EGR blankoff on forward manifold. Manifolds are painted and hoping to reassemble tomorrow.

i did go ahead and get the air rail plugs installed as I am also doing desmog.

install pics to follow.

 

[southerncruiser62]

Well it fit, now on to re-bolting. Happy with fit, only time will tell how the clearance piece of this project went. Hope to be ready to start it up tomorrow morning.

 

[southerncruiser62]

All buttoned up and took for a quick spin. Sounds pretty good idling but as soon as you get above about 1200 it is outright obnoxious. Looking forward to getting exhaust buttoned up. Flanges are mounted and torqued. Really happy with how it turned out, once the exhaust it buttoned up I’ll clean up desmog vacuum tubing.

 

[southerncruiser62]

Finally getting around to posting pics of exhaust work done by Carolina muffler here in Charleston. They’ve done my trucks since being down here, operate just like Henry’s always did in Raleigh. Smooth y pipe transition then went back with factory muffler and clean pipe route, all at or above frame rail. Really happy with overall performance with better flow from 3FE manifolds.

Next is some more interior cleanup and a few gaskets I need to replace.

 

[southerncruiser62]

Few more quarantine updates. I had been toying with a few different headliner ideas and had settled on a foam backed perforated liner but was told that was too basic. Well here is the result of creativity when you take the swine from the pen but not the barn out of the swine. Have a few items to clean up but really happy with the look and fitment.

Also upgraded igniter and coil to the Pertronix 91662LS lobe sending kit with flamethrower II 45111 coil in factory coil location.

 

[GarnerFJ40]

I like it. I didn't notice it as first (I was wondering what was in the box!).

 

[southerncruiser62]

Another little add to the truck for taking kayak out with kids. Didn’t want to advertise for anyone but Mr. T since a lot of people ask me what kind of truck that is. This should clear things up and keep with vintage decals...

 

[lt1fire]

Looking good Greg