Builds "The Survivor" 09/1990 (MY 1991) HZJ77 Refurbishment and Renewal (2 Viewers)

[OGBeno]

Some more updates…

New BMC:

 

[OGBeno]

New PS high pressure line:

 

[OGBeno]

New OEM PS pump and gear:

 

[OGBeno]

New bypass pipe, studs, gaskets and manifold assemblies:

 

[OGBeno]

More reference bits:

And powder coated bits back from the PC folks:

 

[OGBeno]

Exhaust manifold painted and installed. Heat shield installed:

PS pump installed:

Intake manifold holes chased, studs and gaskets installed:

 

[OGBeno]

ARB bumper arrived!! Thanks @cruiseroutfit

 

[SKULLYOTA]

@Onur if you wouldn't mind taking a pic of the injection line routing when you get to that point? I just installed the pump you sold me (i got it rebuilt) and could use a good visual reference again.

 

[OGBeno]

Some more progress on the HZJ77…. Had the grasshoppers over for some assist…. Noico asphalt layer and secondary foam mat….

 

[OGBeno]

New injectors installed. The injectors come with the nozzle crush washer…. Seat goes in as well.

Anti-seize on the threads. Important.

All 6 installed and ready for spill rail and hardliners.

 

[OGBeno]

New steering gear box and pitman arm installed. Toyota marks the sector shaft end and the pitman arm so you are easily able to line things up on install.

 

[OGBeno]

Transmission removed, cleaned and on the operating room table for the split case to come off and be rebuilt onto the new H55F.

Without a lift, really helps have extra hands.

 

[Bludozer]

Don't know how I missed this one going on - I need to visit the 70 series section more often. Looking great so far!

 

[wngrog]

Yep.

 

[OGBeno]

Transfer case disassembly, cleaning and reassembly. Transfer casing won’t be getting PCed due to some time limitations on my end.

I’ll clean it up best I can and leave the patina on extant.

 

[OGBeno]

Don’t forget your 5th gear oiler.

Front output and input seals installed:

Front case housing installed:

 

[OGBeno]

New Sumogear long spline input gear…

This gear replaces the OEM input gear, spacer and PTO gear. A good upgrade if not running any PTO:

New idler shaft, bearings, washers, o-rings, and the idler gears installed:

And your high low gear set with new bearings installed:

 

[OGBeno]

Detent ball, spring and plug for the high-low shaft:

Installed here:

Speedo gear, spacer and washer on the rear output:

You can see here the OEM marking indicating gear tooth count for drive and driven gear:

Input bearing installed:

Make sure to locktite the set bolt for the idler shaft tab…. If that backs out…. The whole thing goes kaboom….

Thanks to my good friend Georg @orangefj45 for the rebuild kit and long spline gear…. Pimp.

 

[OGBeno]

Rear extension housing installed:

Front and rear drive flanges installed and staked:

Input shaft staked and covered:

And complete:

I really wish I could have powder coated the case like I normally do, but due to some life changes we had to cut that aspect short to get the truck out back together and driving. I have a solid drop-dead date of next Weds for this rig…. So lots to do!

More soon.

 

[Felde]

Thank you for documenting all the steps although being under time pressure.
This will be a valuable source for everybody who needs to get into this.
Well done.