Build "The Survivor" 09/1990 (MY 1991) HZJ77 Refurbishment and Renewal

[OGBeno]

Old pilot bearing out using the classic bread trick.

New clutch pressure hose and slave cylinder:

New rear main seal:

New rear plate:

Flywheel machined:

Flywheel installed with new bolts (use locktite…. You don’t want them backing out):

New clutch disc:

 

[OGBeno]

Disc centered with fine spline centering tool and the pressure plate installed:

Straight in shot for the trans input:

Make sure to use new pressure plate bolts: 90119-08134 for the earlier trucks. M10x1.25 for the higher torque engines:

Trans assembly ready to stab:

Clutch fork boot:

Clutch fork and throw-out bearing: lots of anti-seize on all metal-to-metal interfacing surfaces:

 

[OGBeno]

Transmission and driveshafts installed:

New downpipe installed:

Carpet install begins:

Gray parking brake handle boot:

Seats being installed:

And ARB installed:

 

[OGBeno]

More progress tomorrow:

Door and glass assembly
Mirrors
All new door weatherstrips and window runs
OEM roof rack from Oz
Engine bay reinstall
Remainder of exhaust piping.
Electrical
Test driving

 

[LDowney]

...
Trans assembly ready to stab:

View attachment 2795738

Onur,
Good morning. You retained the vacuum shift on the transfer case. Based on my experience with vacuum shift in my 1970 FJ40, I highly appreciate the direct mechanical via a shift lever in my newer Cruisers. Does the newer vacuum shift with utter reliability (even with some binding)? Or were there other considerations in retaining it?

Thanks

 

[OGBeno]

Hi Larry:

Never had any reliability issues with the vacuum controlled transfer cases. So we kept it.

 

[LDowney]

Thanks.

 

[OGBeno]

Lots of parts for the interior and trim today…

 

[OGBeno]

More trim pieces:

All the little pieces matter.

These are 24V courtesy switches: notice the difference between the originals and service replacement part…. Subtle but important changes:

Most interior switches are manufactured for Toyota from their long-time keiretsu supplier Tokai Rika “TR” logo indicates this:

 

[OGBeno]

Lots of weatherstripping installed today….

.

 

[JDM Journeys]

This thread should be required reading for all hzj77 owners, indeed all 70 series owners!

Thanks for the clear and concise pictorial documentation. Not an easy feat when you're elbows deep in there!

 

[OGBeno]

This thread should be required reading for all hzj77 owners, indeed all 70 series owners!

Thanks for the clear and concise pictorial documentation. Not an easy feat when you're elbows deep in there!

Thanks. I try to document the best I can both for the owner of the truck and for others.

 

[FJ73Texas]

This thread should be required reading for all hzj77 owners, indeed all 70 series owners!

Thanks for the clear and concise pictorial documentation. Not an easy feat when you're elbows deep in there!

I agree. This thread makes me want to go out and "refresh" mine.

 

[BinduHJ75]

You're doing a mighty fine job at it too sir.

Thanks. I try to document the best I can both for the owner of the truck and for others.

 

[OGBeno]

Rear vapor barriers installed with butyl tape:

New inner door handle:

Rear doors completed:

 

[Bludozer]

Rear vapor barriers installed with butyl tape:

View attachment 2798258View attachment 2798254View attachment 2798259View attachment 2798255

New inner door handle:

View attachment 2798257View attachment 2798261

Rear doors completed:

View attachment 2798262View attachment 2798264View attachment 2798263

View attachment 2798256

The details are what make threads like these so good. The owner of this truck is incredibly lucky, I hope he has this truck for decades.

 

[OGBeno]

Front LH door handle installed:

Front LH power window regulator and motor:

Glass filler and new channel. Old one was rusty as hell:

Glass needs to be measure for correct fitment:

Installed:

 

[OGBeno]

Window runs installed for the front LH door. This is a two-piece set-up with 2 part numbers:

Long one goes in the main window frame assy:

Small one goes up front inside of the door frame:

Front vapor barrier. These are unisex in that you flip it over to fit either RH or LH sides.

New wire harness clamps:

 

[OGBeno]

Completed. Basically…. Same thing 3 more times and you have rebuilt your doors mechanically and in terms of weatherstripping. My client will be having a stereo installed with speakers so the holes will unfortunately be on each door panel until he gets that done.

Also, these little buggers are easily overlooked:

Two for each front door and one each for each rear door at the top. Nice little touches like this really make me smile.

 

[Rigster]

A thing of beauty...

I love the adherence to TOYOTA genuine...

Ironically, the grunts, swears, and general pain-in-the-ass points of contention are lost in the detailed photos, making this thread to the uninitiated appear that a complete overhaul of a Land Cruiser is a piece of cake.

Which it IS, of COURSE!

Nice work ONUR, keep up the great detailed threads so more of us will be driving around $100,000 LAND CRUISERS!!