After a long detour through my entire charging system, I finally got my IPF harness and headlights installed along with some Hella offroad 80/100W halogen bulbs. The difference is incredible. The FJ40 now has better headlights than my Mazda 3!
In the process of installing the wiring harness, I found out that my alternator was dead, and that my truck was a wire fire waiting to happen. In an effort to not pull a
@Vae Victus, I wound up replacing the externally regulated GM alternator with a 12SI internally regulated one, and installing fusible links on the alternator cable, voltage sensing cable, and main harness cable (the PO wasn't running any). I also added in a full grounding system (bat-tub, bat-frame, frame-engine, starter-frame, and alternator-tub). Added all new charging wire, bypassed the AMP meeter and main harness so I don't melt it with the 94 amp alternator. Also installed a new, not-melted starter cable. There's only room for one truck named SMOKEY on IH8MUD!
I also replaced the turn signals, and installed ground cable from inside the signals to the tub, to avoid future issues with bad/rusty body grounds:
And last but not least - new horns! To replace the single Ford horn that had been wired up behind the battery (as seen in the engine bay shot above)...
Truly awesome to be able to drive at night, and have working turn signals finally! It's the little things.
The next project will be a major one to get this truck mechanically sound - I need to move the V8 backward in the bay about 4-5 inches, reseal it so it stops puking oil, replace the clutch, and check out the transmission...The cruiser fund has a long way to recuperate before all this can happen. I've already got the full
@Downey bellhousing/clutch setup ready to go...I'll need to determine if the 283 is worth saving, or if it's time to ditch it for a 350.
I'll also be swapping out the tranny's top cover to an FJ60 top cover to move the shift tower back a bit, then replacing the leaky exhaust, Ram's Horns all the way back, and changing the driveshaft lengths to accommodate the new (correct) setup.