Since I've found this community to be more than helpful in getting my FZJ80 in tip-top shape, I wanted to share some experience replacing the soft transmission hoses using non-OEM parts as almost all are discontinued. This project started after one of the hoses developed a slight tear and sprayed transmission fluid all over the garage floor and in the engine bay. After cleaning everything up and identifying the culprit (it was the return line from the oil cooler to the transmission hard line), given the age of the vehicle (and likely all of the soft transmission lines) I decided to replace all of the hoses while I was in there. So, in an effort to help others, below are the parts, lengths, and vendors (no referral links) below to save some time and use some high-quality parts. That’s unless @NLXTACY decides to put together a kit (hint hint)!
For parts, I ended up using the following:
For the hoses from the hard lines next to the radiator behind the left side / driver side headlight, they need to be cut to:
If I missed anything, or anyone thinks the process can be improved, please feel free to chime in.
For parts, I ended up using the following:
- 3/8 ID Continental Insta-Grip™ TC Push-On Hose from Abbott Rubber
- 3/8 Precision Brand Unicoi from Amazon
- Spiral wrap hose protector from Amazon
- Replacement clips from Toyota - P/N 90467-A0012
For the hoses from the hard lines next to the radiator behind the left side / driver side headlight, they need to be cut to:
- 24cm (10in)
- 36cm (14in)
- 41cm (16in)
- 44cm (17in)
- 61cm (24in)
- Disconnect and remove battery and tray
- Disconnect the fan and fan shroud
- Loosen the belts and then remove the fan and shroud
- Drain radiator and remove. One may be able to make the replacement without removing the radiator, but I had already determined to flush out the system (will provide details in a separate thread) and realized it would be too challenging to do so with it in there
- Remove the grill
- Remove the left side turn light and headlight
- Remove the turn signals and the turn signal assembly
- Cut the front lines with a box cutter or other blade being careful not to cut to the metal
Warm up the front hoses in an oven to the lowest setting available to soften the rubber and make the process infinitely easier - Wrap with hose protector where hoses bend or can rub against metal
- Coat the hard lines and inner hoses with some transmission fluid to ease them back on and remember to slip both clips on before installing
- Reconnect the front lines, starting the with bottom / shorter hose
- Cut the rear lines, again being mindful of the hard lines
- Heat the remaining three hoses, and coat with the hard lines and inner hoses with transmission fluid as noted above
- Connect the lines with their corresponding length locations starting with the lines leading to the transmission,
- With the two transmission lines installed, slip two clips on, but not all the way
- For the line leading from the transmission to the radiator on the right side, attach the Unicoil and bend close to a 90 degree angle as in the photo below. Once bent, slip the two remaining clips
- For the short hose from the left-side radiator to the hard lines, slip two clips on the hose, and connect the hose to the furthest hard line leading to the front hoses, again remembering to have both clips installed
- For the line connected to the transmission hard line, connect it to the closer hard line. Then wrap the line with hose protector
- When ready, reinstall the headlight, turn lights, and radiator
- Connect the two lines to the radiator - the curved line to the right side, and the short line to the left side
- Re-fill the radiator with Toyota pink or red
- Re-install the fan and shroud
- Tighten the belts and tighten the fan shroud nuts to spec
- Re-install the battery tray and connect the battery
- Refill the transmission with any lost transmission fluid
- Start the engine and observe for leaks
- Enjoy and take pride in the work you just accomplished
If I missed anything, or anyone thinks the process can be improved, please feel free to chime in.