got a 40 - now it begins

[Rezarf]

Sorry man, set backs like that really, really, really stink.

You'll get it sorted out. What do you need that is flywheel related?

It looks really good, and when you hear it fire, it'll all be worth it.

 

[RicardoJM]

Bummer. Good news is that the new components will last that much longer. .

 

[treerootCO]

We can rebuild him, we have the technology... and now a completely unrelated reference to cheer you up.

 

[simps80]

I think that picture you posted was random...it instantly reminded me of something that I think is TOO obscure to be related...but the resemblance is uncanny....

Plus I think you are too young to know this early 80s lee majors tv favorite....

But that truck reminded me right off of it.....

Anyone guess????

The 80s had lots of good car tv shows!

 

[treerootCO]

That was the reference I was going for My pic must have been someone else's rendition on that truck

 

[nuclearlemon]

was that the fall guy?

 

[simps80]

yes the fall guy!!

I think I found some toys Mike doesn't have yet

to chat!

 

[simps80]

Made up some ground and then sone small progress.

At last post the distributor snafu ruined the cam gear and oil pump.

I ordered new pump and new cam.

Back is still pretty bad..actually injured lower right side..doc said its muscle this time which is good..so the kids helped me a lot putting new cam and pump and buttoning back up.

I think I enjoyed them helping more than they enjoyed helping.....

Took some more time away....
Today decided to get it off the stand and started putting the back together.

Read good tip on pilot bearing...fit it to input shaft of transmission before putting it in.

Wouldn't have thought of that and sure enough input shaft needed a lot of Emory clothing before bearing would go on..

This pilot bearing is all the way in pretty sure right?

After that mounted up the bell housing..another torque spec it took me a long time to find..47 ft lbs for the 12x1.75 bolts..

Finished off todays work putting on rear mounts..
Then the girls helped me get it lined up ok on the stands..
Leaving hoist and chain in place as safety

 

[simps80]

Also ordered one of the blower housing rebuild kits from metrictlc..

Took it apart cleaned it all up..used some plastic paint and cleaned up the duct work..turned out pretty good

Oh yea and new firewall grommets
Oh yea.. new oem toyota rag joint too

 

[Crash]

Looking good, Mike. A long time ago, I found that wearing a dirt bike riding belt helped keep the back pain down when working on trucks. The extra support helps.

 

[simps80]

Yea injury number 3 was because I tried to play golf and knew I shouldn't cause it was too soon after injury number 2.

I was "protecting" my left side swinging weird and tore a muscle on the right...

I am realizing I am getting too old to treat my body the way I did in my twenties..

Strengthening my core and losing weight is my focus now.

But I am determined to get as close as I can to driving this to the rally..
I will have to check into that motorcycle belt.

 

[nuclearlemon]

done yet?



done yet?





done yet?

 

[treerootCO]

actively working on it now....

 

[simps80]

Put flywheel in torqued to 58 ft-lbs with blue loctite pushed tabs up on lock plates.

Then went about the business of figuring out the throwout bearing. I used this old piston pin from a mack e6 which was exact diameter and tapped the collar out from old bearing.
Then used the old bearing to press the new one onto collar.

.

The next day I called in the air support.
Mike and john came over to lend me some massive help.

Started by inspecting the internals of the tcase and transmission then put new gaskets and front seal in.

Ignore the exxon oil slick..lol

 

[simps80]

Next up went clutch disc and cover.

Sprayed down flywheel and clutch with brake clean then bolted it in with fresh toyota 8mm bolts torqued to 16 ft lbs. Very slowly torqued one by one in even sequence.

Somehow missed the pics of that.

Next we slid this mess together and with the other two that went much smoother than I imagined it. Torqued the trans to bell fresh bolts to 62 ft lbs evenly.

After that it was time to finally put it in the truck..

The truck was pretty high up on jack stands so we left the back up and dropped the front down which really helped with the angles. Used some ratchet straps for safeties under the engine..then once it cleared the front diff we dropped it down slowly and brought trans up with floor jack. It swung into place with minimal trouble. It was very helpful to have 3 sets of eyes and hands!!

At the stopping point last night we had this! !

Again huge thanks to Mike and John..big times

 

[wesintl]

OMG, that's awesome!

 

[subzali]

OMG, that's awesome!

x2, so exciting!

 

[Rzeppa]

Lots easier without the fenders

 

[Hulk]

Super cool. You're going to have a dream FJ40!

 

[simps80]

Thanks everyone for the encouragement and nice words.

Made some more random progress.

Took apart the inside to clean out the tank..
The inside of the tank was perfect despite the old gas in there.

The outside of the tank had some surface rust corresponding to the felt spacers.

The floor pan had some surface rust underneath the felt too.

Cleaned both up then used rust converter then sparingly covered in a quality epoxy.

The history lesson on the floor pan was interesting..
This Wyoming rancher liked poker, cigarettes, and beer..good trifecta.. Lots of old pull tab can tops and some miller bottle caps and several matchbooks from some laramie "points of interest" were found.

Meanwhile there has been an ongoing war between me and the egr system.

I had a couple egr sets i have been acquiring. So I have been using components of each to try to make one usable. I needed the manifold pipe off this one but after a week of heat rust penetrant wax a 4 foot cheater a new expensive wrench and lots of fruitless effort..

Mike came over and assessed that the shock was being lost by the movement of the wood bench mounted vise.

We took it out front and parked a tire on it and eventually the 4 foot cheater and new 1 7/16 wrench (36mm wrench not available quickly) got it loose.