Builds TheAmigo's 1981 FJ40 Build Log (1 Viewer)

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Driver’s side disassembled. Passenger’s tomorrow. That was the single messiest thing I have ever done.



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Front axle housing empty and ready for a bit of cleaning prior to blasting and coating. Doing the rear housing tomorrow.

Since this is my first time I was able to compare the excellent rebuild kits I received from @cruiseroutfit with what I took apart so that I’m able to wrap my head around everything. Looking good!

I have a great powder coating company recommendation but they’re about two hours north of me. If anyone knows of anyone near Tacoma I’d be interested in hearing about them. I need to find someone and visit their shop this week.


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I bought this great kit today from Napa. Really worked great on the races and seals.

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-Nathan
 
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Got the broken pinion shaft bolt out!

Drilled a small pilot hole through the broken head, put it back in and used it to drill a centered pilot hole in the bolt shaft, then drilled out the shaft with a larger bit, then inserted the Irwin Hanson extractor, set it with a hammer, and backed it out.


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Nice job.
 
Need a new bolt?

Ha! Yeah, I was gonna give you a call soon. I also found a pinion thrust washer in the bottom of my diff when I took the cover off. Quite perplexing. I don't see any immediate damage but I'll need to check things out and see how it might've affected it.
 
Let us know, we'd love to help.

Could you start autographing the boxes so that I can sell them on Ebay to offset the cost of the parts? :)

So, we started watching XO just last month with the current season, and by now we watched the seasons in reverse and are about to wrap up Alaska/Yukon. Great stuff.
 
Could you start autographing the boxes so that I can sell them on Ebay to offset the cost of the parts? :)

So, we started watching XO just last month with the current season, and by now we watched the seasons in reverse and are about to wrap up Alaska/Yukon. Great stuff.

Ha.

Right on, thanks for watching!
 
Now that it's 100% apart I get to start putting it all back together! I love the big Eastwood media blast cabinet I got, along with the junky but functional 20 gallon part washer from Harbor Freight. I'm using PSC 1000 as the degreaser/cleaner. Great stuff. High flash point and almost no odor.

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-Nathan
 
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Got the broken pinion shaft bolt out!

Drilled a small pilot hole through the broken head, put it back in and used it to drill a centered pilot hole in the bolt shaft, then drilled out the shaft with a larger bit, then inserted the Irwin Hanson extractor, set it with a hammer, and backed it out.


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Great save!
 
@theamigo, Andy told you that he blasts all the parts prior to coating right? I saw you blasting the brake drum above and didn't know if you planned on coating that or not. If you are, it'll certainly save you some blast cabinet time.

On the axle tubes, plan on having to wash the internals out about 12+ times with a pressure washer and some sort of degreaser. They WILL have blast grit in them and it was b**** to get out. That's the last thing you want running through your diffs though.
 
@theamigo, Andy told you that he blasts all the parts prior to coating right? I saw you blasting the brake drum above and didn't know if you planned on coating that or not. If you are, it'll certainly save you some blast cabinet time.

On the axle tubes, plan on having to wash the internals out about 12+ times with a pressure washer and some sort of degreaser. They WILL have blast grit in them and it was b**** to get out. That's the last thing you want running through your diffs though.

Yeah, I didn't take the drums in. And I'll be sure to wash the housings out. Thanks.
 
Today is a huge milestone! Got my frame, axle housings, and front bumper back from powder coating. Looks great. Also received a new OME 2.5” Heavy suspension from @cruiseroutfit (ters).

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