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

[theamigo]

Birfields apart and cleaned. Looks like they’re in good shape but man did I have to wail on them(brass drift, yes) to get them apart.

Will be calling @cruiseroutfit tomorrow for axle clips and a few other consumables for my hubs and maybe a tcase flange? We’ll see.

 

[theamigo]

Quick update. Got the front axle finished.

I bought a knuckle centering tool. Pretty fun to use.

Testing preload before taking measurements to be used as part of the process of determining shim thickness:

Pressing in the new spindle bushing in the new spindle. Old one had some slight scoring and wear - seems the bearings spun.

I ordered the full knuckle rebuild kit from Cruiser Outfitters, along with a few additional things like the axle spindle nut kits, and new detent spring and balls for the ASCO hubs, and an o-ring for each.

Took the birfields apart and cleaned, then applied new grease and new c-clips inside.

Some of the knuckle rebuild kit...

Shimmed properly. New knuckle studs too.

 

[theamigo]

Spindles with the knuckle internals greased, and all gaskets and seals installed.

Top down, before the locking hubs were installed.

Completely disassembled them, cleaned them inside and out. Media blasted, low-speed brass brush, then clear coat. Before and after:

Done.

Front looking good!

 

[theamigo]

Time for an update.

I'm about 250 hours in at this point, says my spreadsheet.

New hardware for the rear drums. They look nice and clean now!

Decided I didn't like my existing axle shafts, so I bought new shafts from SOR. Sadly, they were both a bit shorter than the stock axles, but I was able to get the right c clip installed on the long side despite its slight difference in length. I decided to reuse my existing short side, as it is now clean, with fresh bearings and seal, and wasn't leaking when I took it out.
SOR was very helpful and treated me right when I called them with my issue.
Pressing on the new studs, along with the dust shield and paper gasket.

Passenger rear looking good!

 

[theamigo]

Tires are on, diffs are full of gear oil, ARB locks up really nice, and I'm a happy guy.

Up next, gearbox and transfer case! Thanks to @cruiseroutfit!

 

[theamigo]

Started disassembling the transmission and transfer case today.

 

[theamigo]

Into the tcase and gearbox.

A few questions... 2nd and 3rd seem to have a small notch worn in the outer part of the tooth. Doesn’t seem problematic. Normal? Cause?

(Lower snap ring removed)

Transfer case...

 

[tstepp920]

Started disassembling the transmission and transfer case today.

View attachment 1697939 View attachment 1697940 View attachment 1697941 View attachment 1697942 View attachment 1697943

I am terrified of doing this.

 

[theamigo]

I am terrified of doing this.

I figure that if I can rebuild a diff to spec then I can rebuild these things. Granted, I've got a lot of proving to do once it's all back together but that's part of the adventure!

Get a rebuild kit, the necessary tools, a factory service manual, and have at it.

I've had so much fun so far, and I've got a lot left to do.

 

[theamigo]

More parts from the snappy shippers at @cruiseroutfit!

Brake hoses, full linkage kit, front & rear motor mounts, center arm rebuild kit, and a few small odds and ends.

 

[theamigo]

Also rigged up a bearing puller for the transmission. Has longer arms for the output shaft.

 

[theamigo]

And the input shaft. Tapped a little from the inside, then this:

Didn’t drop any.

 

[Bad Mojo]

And the input shaft. Tapped a little from the inside, then this:

View attachment 1708696

View attachment 1708695

Didn’t drop any.

Do you have a part number for the bearing splitter you used for the front input bearing?

 

[theamigo]

Do you have a part number for the bearing splitter you used for the front input bearing?

OTC 1123 Bearing Splitter - 1/2 to 4-5/8

Not quite big enough to fit perfectly but it bit just fine. I also used it to grab the output bearing so that I could press the shaft into the case, then once the shaft was free of the bearing I easily tapped the bearing out.

 

[theamigo]

Transmission apart. The case parts are in the parts washer and will be blasted and repainted.

 

[theamigo]

Cleaned, blasted, cleaned again, painted, and ready for reassembly.

 

[Rock40]

Lookin' awesome!

 

[theamigo]

Decided to keep it natural with the split
Tcase finish. I soaked it in the parts washer, brushed a bit to get the gunk off, then blasted with 80 grit glass beads(which is all I use really). Then cleaned it with air and lots of cleaner to get the sand and remaining spots off. Am now going over it with one or two fast wire brushes to give it some gloss.

I may finish with a clear enamel, like I did the front ASCO hubs.

Half and half.

Before and after brushes.

Done.

 

[theamigo]

Time for an update...

I got the latest small batch of hardware back from plating. Very happy with it, once again:

 

[theamigo]

I also started reassembling the transmission this weekend.

My only major hiccup was that, really, the version of the FSM I have is terrible and doesn't match up with, I guess, the newer H42 that I have. The springs, shift fork shafts, locking balls, and interlock pins were all in different places(or were different sizes) than what was mentioned in the manual. Mud helped a lot, especially a post by @Vae Victus. Thanks!

Other than that, everything was within tolerance. Frankly it looked readly good other than the dirt and grime which are now gone.

Working on the shift assembly...

Setting the countershaft in place... reverse idler gear and shaft already set.

I apparently didn't take any photos of the output shaft, but here's a nice one of the input and roller bearings ready to go in.