The dead FJ60

[LoafNvi733]

I guess this isn’t really a build thread just yet, more like reviving dead truck and then building one hell of an off-road capable vehicle. Today since I had the holiday off I decided to tackle the carburetor and give it fresh plugs and wires. While I had plugs out I checked compression and pretty much across the board I landed in the happy zone of 140 psi and each one was damn near the same.
So, the carb.. it was filthy, dirty and I didn’t want to take the thing apart out of fear of messing up. I hesitantly began the process and worked step by step and as clean as I could so I could make this poor truck run. I got the bad boy cleaned and holy cow, between the new dizzy rotor and plugs and wires AND a clean carb oh AND clean gas after flushing the varnish out BOOM! This truck runs a million times better than when I first started into this.
It’s given me the motivation to keep moving forward with this project. I needed a win after the leaf spring fiasco.

 

[Capriblue45]

Definitely a buzz kill. Listed them for sale here and marketplace for 55 less than I paid. The company I bought from wants me to pay for shipping and that’s gonna be at minimum 100 bucks

If you are looking for a complete set of 4 springs and shocks for your 60 I have the ones that were under my 60 before I did the 80 series conversion. I believe it is a 2" lift Ironman set with around 20K miles on them, they were on the truck when i purchased it. DM me if interested.

 

[cruiseroutfit]

Well, after more digging and a lot of b*tching i learned these springs are not for a 60… but they fit a 40… what’s even more frustrating is I verified with the VIN that these would fit. This is the closest I could get before calling the part shop I bought from.

Sorry to be the bearer of said bad news but at least you knew to cut your losses and quite trying to make em fit.

 

[LoafNvi733]

Sorry to be the bearer of said bad news but at least you knew to cut your losses and quite trying to make em fit.

No seriously thank you for telling me! I would have been fighting this thing and kicking myself thinking I’ve done something wrong. I appreciate you and your team!

 

[LoafNvi733]

Looking for a little guidance. I accidentally pulled this plug off and need help with identifying the right way they go back into the plug! These are situated over the transmission and in between the transmission and the tunnel. I’m assuming is a 4wd switch to light up the dash since I don’t see it giving me the 4x4 when I put the truck into 4x4.

Thanks!

 

[Capriblue45]

That looks to be the wires that run to the 4wd switch, it is on the passenger side of the Tcase. Those should go into a round barrel looking connector routed above the transmission. The switch can be unscrewed with a big adjustable wrench but expect to lose a bit of gear oil out of the hole. there should be a wiring loom running down the passenger side of the firewall that runs to both the reverse light switch and the Tcase 4wd switch above the transmission. I will try to get you a picture when I get in my shop later this morning.

 

[LoafNvi733]

That looks to be the wires that run to the 4wd switch, it is on the passenger side of the Tcase. Those should go into a round barrel looking connector routed above the transmission. The switch can be unscrewed with a big adjustable wrench but expect to lose a bit of gear oil out of the hole. there should be a wiring loom running down the passenger side of the firewall that runs to both the reverse light switch and the Tcase 4wd switch above the transmission. I will try to get you a picture when I get in my shop later this morning.

Thank you! Yeah that’s exactly where those came from. I’m just not sure what the orientation is for the barrel connector. The portion on the TC is still good, it’s the portion that is attached to the harness that I need to figure out what the orientation is. Granted I could push them in and hope it’s the correct way but I hate guessing.

 

[Capriblue45]

I looked at my 4wd switch and my colors are different than yours. Are you sure this is not for the reverse switch?

 

[LoafNvi733]

Well, after figuring out the exhaust gasket donut was fried (I’m stupid and love to do jobs twice) I ordered a new one and in the process of installing it on the one piece exhaust the PO was oh so generous to weld up for me I snapped the exhaust at the muffler. Was it on purpose? Absolutely not but it gave me the space I needed to sand and bevel the manifold downpipe to get the donut on. Here’s a fun one, I’ve cleaned EVERY nook and cranny out of mouse house and seed hoards, well the mouse gods gave me another gift in the muffler in the form of a fully packed muffler absolutely full of seeds. Remember, this rig sat in a field for 12+ years. I started twitching and seeing things that weren’t there, either from the propane heater I have in my garage or rage from finding the motherlode of mouse seed hoard. I guess a solution to an exhaust gets added to the whiteboard.

 

[LoafNvi733]

I plan to see what it is later tomorrow once I’m home from work! I’m hopeful it’s an easy switch of two wires to figure out which goes where. I’ll need to put the front end up and see if it’s the fwd switch or reverse. The rear end is still apart

I looked at my 4wd switch and my colors are different than yours. Are you sure this is not for the reverse switch?

 

[LoafNvi733]

Figured I’d chime in with an update..
last weekend I went up and visted @Capriblue45 and he gave me a great deal on a used Ironman 4x4 2.5in lift leaf spring kit and I got home and installed the rears. What a difference! The fronts still need some but I’m on a budget so I have to wait for payday to order bushings and shackles and the remaining items to finish the front. I managed to do an extensive amount of research between picking Capri’s brain and MUD I managed to find a good set of wheels for the 60 as well. The wheels came off a 2014 FJ and fit absolutely perfect! I’m curious, to those running 17in wheels, what tire sizes are you running with a 2.5in lift? Love the look of these wheels but might paint them grey in the future. One more step closer to having my 60 be my daily driver! On another note, who’s willing to help me get the passenger door and fender straight or knows a guy who can do work, I’m not looking for perfect here just so the door stops hanging up on the fender.

 

[NØIDX]

Yup, just like his DaD.......Patience my son.

 

[LoafNvi733]

Yup, just like his DaD.......Patience my son.

Dad! Welcome to the forum. There’s a lot of great information for you here and also it’s pretty fun to read other folks builds. Happy you’re here!

 

[LoafNvi733]

Today I finished the front lift install, what a beast im building! For my my first Offroad build I’m pretty impressed with how well it’s coming along. I’ve been tinkering here and there since my last post and have done little detail things and troubleshooting. I figured out the temp gauge not functioning and I was surprised to see it really was because of a missing thermostat gasket. I installed a 180° thermostat in prep for emissions testing. I also took the time and installed the muffler but need to figure out how to mount the tail pipe since I have to move it thanks to the larger shackles in the rear. It’s coming along, and further than I originally planned to go with this truck. Take a peek at the difference in height and overall size compared to the wife’s RAV4! I do love that RAV though.. figured I’d post a pic of me and my daughter too, she’s been watching here and there when I’m not running an impact or grinder.

 

[LoafNvi733]

Well, it’s been a bit and I’ve been busy. Busy between work and trying to be a good dad. I finally have a window of time i can tinker more with this beast and tonight I got the radio working. The 60 came with a Boston acoustics speaker system tied into a 300 watt pioneer amplifier. The head unit was fried but thankfully the PO had done the hard work for me and I had zero trouble chasing two remote hots and the RCA cables.
Now onto the tech part. I ordered a new carb that is meant to be installed for a desmogged engine, and of course we live in the beautiful state of Colorado where emissions passing is critical. However I’ve been studying the carbs and it looks like I could almost move all the smog stuff onto the new carb. The linkages match, and if im right I should be able to just swap over a couple parts from the old carb into the new one. Has anyone done this or should I just desmog and register elsewhere?

 

[LoafNvi733]

This weekend I put the Chinese carb in and began testing and tuning and surprisingly even being smogged I was able to get it running pretty well! Drove over and seen @timmbuck2 at his shop. I took the time to finally put the new tires on and what a difference it makes in appearance! I began putting the carpet kit in and it’s definitely more challenging than anticipated. Got 2/3rds of the way and stopped at the driver/firewall because I was tired and was starting to get irritated. Anywho, here’s some pics to tantalize your taste buds. Plus a little bonus of what was hiding under the carpet..

 

[Cruisertrash]

Well, it’s been a bit and I’ve been busy. Busy between work and trying to be a good dad. I finally have a window of time i can tinker more with this beast and tonight I got the radio working. The 60 came with a Boston acoustics speaker system tied into a 300 watt pioneer amplifier. The head unit was fried but thankfully the PO had done the hard work for me and I had zero trouble chasing two remote hots and the RCA cables.
Now onto the tech part. I ordered a new carb that is meant to be installed for a desmogged engine, and of course we live in the beautiful state of Colorado where emissions passing is critical. However I’ve been studying the carbs and it looks like I could almost move all the smog stuff onto the new carb. The linkages match, and if im right I should be able to just swap over a couple parts from the old carb into the new one. Has anyone done this or should I just desmog and register elsewhere?

I hate to be the bearer of bad news, but with that carb you’re definitely going to have emissions equipment compromises, and a full “desmog” is probably going to be the easiest route to make that thing work. I think there are 6-7 vacuum connections that are missing so it isn’t possible to incorporate your vacuum driven emissions stuff. Pretty sure the Chinese carbs have one vac nipple total (the Japanese-made Fuji carbs too), for the distributor advance. That’s going to affect the EGR, Air Injection, and a few other systems, all necessary stuff if you want to pass a smog test. It has no AC idle up vac pot - I’m not sure if your AC works, but it won’t anymore, not without the truck suffering or stalling at idle. It also looks like it does not have the choke breaker and choke opener, right? There’s no float bowl vent so you’ll have to cap some things off at your evap canister. Finally the electrical connector for the fuel cut solenoid might need to be changed.

I’ve tried to pass AirCare with some of my smog equipment defeated and it doesn’t work. I suggest getting the 2F Emissions manual and reading a LOT of Mud threads about desmogging. There are MANY places that process can go wrong and leave you with a truck that runs like shit, and even when done “properly” there are side effects. You’ll also have to register the truck elsewhere if you’re on the Front Range.

Or … don’t lose the forest for the trees and just rebuild your stock Aisin carb. It seems like the path of least resistance. All of the things I mentioned above are the price to pay for the “convenience” of trying to make that knockoff carb work.

Note: I’ve heard quite a few people say the accelerator pumps on those carbs do not work straight out of the box. FYI City Racer has a nice replacement with a leather seal.

 

[LoafNvi733]

I hate to be the bearer of bad news, but with that carb you’re definitely going to have emissions equipment compromises, and a full “desmog” is probably going to be the easiest route to make that thing work. I think there are 6-7 vacuum connections that are missing so it isn’t possible to incorporate your vacuum driven emissions stuff. Pretty sure the Chinese carbs have one vac nipple total (the Japanese-made Fuji carbs too), for the distributor advance. That’s going to affect the EGR, Air Injection, and a few other systems, all necessary stuff if you want to pass a smog test. It has no AC idle up vac pot - I’m not sure if your AC works, but it won’t anymore, not without the truck suffering or stalling at idle. It also looks like it does not have the choke breaker and choke opener, right? There’s no float bowl vent so you’ll have to cap some things off at your evap canister. Finally the electrical connector for the fuel cut solenoid might need to be changed.

I’ve tried to pass AirCare with some of my smog equipment defeated and it doesn’t work. I suggest getting the 2F Emissions manual and reading a LOT of Mud threads about desmogging. There are MANY places that process can go wrong and leave you with a truck that runs like shit, and even when done “properly” there are side effects. You’ll also have to register the truck elsewhere if you’re on the Front Range.

Or … don’t lose the forest for the trees and just rebuild your stock Aisin carb. It seems like the path of least resistance. All of the things I mentioned above are the price to pay for the “convenience” of trying to make that knockoff carb work.

Note: I’ve heard quite a few people say the accelerator pumps on those carbs do not work straight out of the box. FYI City Racer has a nice replacement with a leather seal.

Thanks for the input! Who’s our rebuilder here? I know it’s missing at least one or two parts. I’m dreading the aircare biz as I’m sure everyone else who has to do it does too.. I was actually really surprised with how well the truck ran after I set the idle correctly with just plugging a few lines and running a vac line directly to the dizzy advance. I also bought the china carb for parts that are missing on my stock carb. I’m familiar with carbs and rebuilding them but these are different than what I’m used to tinkering with. Regardless I’m not out a bunch of money on the china carb so at the very least it was a fun experiment lol

 

[timmbuck2]

This weekend I put the Chinese carb in and began testing and tuning and surprisingly even being smogged I was able to get it running pretty well! Drove over and seen @timmbuck2 at his shop. I took the time to finally put the new tires on and what a difference it makes in appearance! I began putting the carpet kit in and it’s definitely more challenging than anticipated. Got 2/3rds of the way and stopped at the driver/firewall because I was tired and was starting to get irritated. Anywho, here’s some pics to tantalize your taste buds. Plus a little bonus of what was hiding under the carpet..

Great to see you and your pup and finally see the 60 in action!

 

[NØIDX]

Have you thought about the braking system? Since converting to ABS is out, I hear a 4Runner master and going to rear disks is possible.