BamaBleach's FJ40 buildup

[BamaBleach]

Well I joined this forum back in the day when I had a FJC. During that time I also bought a '73 FJ40 and started building it up. I've since sold the FJC but I still have the 40.

I still hang out here and even put on a ride for the FJC crowd in February so I thought I might has well post up my build thread. It's not as tasty as BellyDoc's 40 but what is?

I'm copying most of this from my thread on IH8MUD so if I reference mud I hope you understand. I also try to go through and take out some of the acronyms since many over here may not know what they mean.

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My story from a "stock looking" FJ40 to a basic Spring Over Axle (SOA) conversion to my current project of installing a 3FE (4.0 fuel-injected motor found in 62 series and early 80 series Land Cruisers), Marlin Toybox, full cage, and 60 series rear springs.

I bought this '73 FJ40 in January 2007 without much knowledge of Land Cruisers and had never once logged onto IH8MUD. I grew up around Toyota trucks so I knew I couldn't go too wrong. I quickly found this site and started researching what I had and what I needed/wanted. The process continues to this day.

Pics from the PO's for sale ad:




Specs:
2F engine (inline 6) with H42 4 speed tranny.
Everything else (mechanically) was basically stock.

Got it on what I thought was a pretty good deal. The PO was moving to China in 2 weeks so he was anxious to move it. We made the transaction and I drove this baby home about 100 miles. My first real experience with drums brakes on all 4 corners and manual steering.

[BamaBleach]

I wanted this thing to be a more capable trail rig so I started researching what my next move would be. I took it to the trails in it's "stock" form a couple of times just to get a feel for it.

I quickly realized that power steering would be one of the first things I added. I also scored a mini-truck axle from a friend so I could gain disc-brakes.

Also decided to go with a spring over to clear bigger tires. My dad has performed a few SOA's in his time so I was exited to learn.

From Jan '07 - Oct '07 it made this transformation:
- mini-truck disc brakes
- 4.88 ring & pinion gears (R&P)
- aussie locker in the front and welded in the rear
- Saginaw PS (power steering) with 4x4lab hysteer kit (4x4Labs.com)
- shackle reversal (SR)

Pics from the shakedown run:

[BamaBleach]

I drove the Cruiser in this condition for sometime. The only major problem I had was the fault of my own stupid mistake. In my excitement to wheel my rig I failed to fab up an anti-wrap bar and I paid dearly. I snapped my rear pinion on the side of a mountain during a night run. If you're going to go Spring Over Axle, do yourself a favor and fabricate an anti-wrap bar! I got away with it for a few months but it eventually bit me.

Once I recovered from that I wheeled it for about a year without many problems but like anybody with a Cruiser I started developing a list of things I wanted/needed.

- lower gears for crawling
- an alternative to the hardtop (so top heavy)
- get a little lower center of gravity
- get a little longer wheel base

I was also battling an overheating issue that was getting annoying.

Pics from a wheeling trip in Sept 2008 with SMC:

[BamaBleach]

So I discovered that I had a crack in my block and I acquired a major oil leak(separte issues). So earlier this summer I decided it was time to start the next wave of mods. The first thing I did was buy a digital camera of my own so I could start to actually document the build process.

I also located a 1989 FJ62 with no title, a bad tranny, 146k miles, and a good price. So I borrowed my cousin's truck and my dad and I went and pick up the new heart for my 40

Here's a cellphone pic:


I also ordered one of these from Toyota (apologize for another cell phone pic):

[BamaBleach]

So Dad and I got to work on pulling the drivetrain from my 40. Growing up I didn't do much wrench turning at all. Sure, I might hand Dad a wrench now and again if he was working on one of the family cars or fixing one of our 4wheelers but I really didn't show much interest in it.

This is the part of the story where I stop and say that the greatest part about all of this is the quality time I get to spend with my family and friends (especially my Dad, who is both). I still don't know much about working on Cruisers and it still takes me forever to do simple tasks like taking out a drive shaft but I've learned so much since getting into this stuff.

So here's pics from the first motor pull I've every been a part of:

Fixing to drain the rad


Everything disconnected and out of the way


The new home of the 3FE


Yikes! Time to do some cleanup

[BamaBleach]

About this time I made a purchase on MUD from LukeZero. He had a toybox in a Cruiser he had purchased but since he was going to be changing out the LC rear axle to one with a centered rear diff he didn't need the LC t-case or adapter plate that mates to the toybox.

So I took it off his hands (he even cleaned his up for me!)


So I contacted Marlin Crawler and got what I needed to adapt the H42 to the toybox

[BamaBleach]

Dad works at a machine shop so he mentioned sandblasting my t-case to try and clean it up some. The H42 needed to be separated from the t-case anways to make room for the Toybox so with a FSM (Factory Service Manual) in hand we went to war.

I've got pictures of most of the steps for removing the t-case but I wanted to focus on what we used as our puller ( $8 harbor freight puller and three home made tabs). Worked like a charm!

[BamaBleach]

I also decided to clean up the engine bay on the 40:



Now it was time roll the 40 out and pull the 62 in. Pulling the 3FE was done last weekend and pretty much gets this thread up to date on where I'm at now.


My 2nd motor pull ever



Had a good crew helping out
Mt DEW in the blue shorts (my Dad)
dwh84 on the creeper
rockrebel wearing the hat


Not sure what the load rating on that bar stool is


What's left

[1911]

Great build!

The 3FE is a super great motor; I would love to put one in my 40. You will need to put an oxygen sensor in your exhaust for it. Probably be best off to use the wiring harness from the 62 also.

I'm envious of your Toy Box. Where are you going to put the gas tank now?
I don't want to move my gas tank, so I'll be going with an Orion transfer case instead of a Toy Box.

Keep posting reports and photos please.

[FJCamel]

You have been busy, nice work.