Tonto- Our FJ40

SOAZ

Tim and Kelsey get lost..
Well, I haven't done a build thread in a long time. This will be more of a break it and then repair it and slowly, but surely restore it... thread.

Prior 4runner build thread is here: http://forum.expeditionportal.com/t...d-At-Molasses-pace?highlight=4runner+molasses

A little background on the FJ40 we're calling Tonto. Well, it's Tonto Rockford for long. Kelsey and I couldn't decide which name fit best.
http://forum.expeditionportal.com/threads/162597-Taking-a-chance-on-an-old-truck

Or, if ya like, the wife is a better writer than me so she got her story put on Petrolicious: https://petrolicious.com/articles/this-reader-took-a-chance-on-an-old-fj40

Here is a short summary of that thread, but basically:
" A buddy of mine is a Toyota Master Mechanic and has owned his own shop for nearly 30 years. He’s the guy who reads service manuals on new cars and sends corrections to Toyota. He is absolutely meticulous, so when he called and told me there was a cheap, CHEAP FJ40 going up for sale I listened. He said the truck would need a LOT of work, but that he’d rebuilt the engine and drive-train to the tune of nearly $15,000 back in the early 1990's. Now it’s been sitting for years and the owner only wants a fraction of that long ago repair bill to sell it.
This certainly seemed like a good deal, but I wasn’t so sure. How bad was it, how many tens of thousands of dirt miles had it covered since the 90's!? The owner used the truck exclusively to get him from Tucson the 100 or so dirt miles to his ranch complete with a dirt airstrip and hangar.
Now he lived back east and so I was going to be looking at, buying and removing a truck from someone’s property without them there and without ever having so much as met them. It all seemed a bit scary, but something drew me to it. Maybe it was just my buddy. Anyone who get’s flown all over the country to work on others vehicles has a certain mojo when it comes to the vehicles they’ve laid hands on."


Here's how we found him:


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At least he spent his life in Arizona. Considering he was once a soft top the mismatched red hardtop was actually nice to have. Maybe that's why we only found 4 mice in it instead of more? Ha!

Before we even drove home we changed every fluid in him as well as the air, fuel and oil filters.
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We got right down to trying to "baseline" ol Tonto a bit. I wanted to get the truck to somewhere where I could trust it to go on adventures. Then all of a sudden a pushrod snapped. Oops!
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We pulled the head and had it redone by a local shop. All set there we put it back together and still heard a knocking. Dammit!
 

SOAZ

Tim and Kelsey get lost..
Well, I pulled the oil pan to see "who's there?" and found it. A nice rod knock with a gouge in the cylinder wall of #6 (The one all the way to the back).
Shoot! Well, ol Tonto decided he didn't like that piston so we had to have that #6 sleeved and redone.
On the plus side, we know have some new wall art:
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All of this practical and purposeful burning of money made me want to do something to ol Tonto that made him feel good. You know, sort of give him that tummy tuck he'd always wanted since growing old and flabby. So, I put some H4 headlights in, found a bezel so he wasn't naked anymore and got him some non-rotted tires and proper wheels/hubcaps. Now that we're nice and broke, he does look good.
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With these aesthetic improvements we decided to take him out for a walk for the day. He did great.
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He was happy. We could tell he was proud. I think he sat an inch taller with pride now. Okay, maybe not, but you see it don't you???

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Using a truck makes all of the hours turning wrenches and $'s burning worth it.

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SOAZ

Tim and Kelsey get lost..
Next up on the list was the fact that Tonto had a nice big Aux Fuel tank that wasn't being used because the seller mentioned it hand't been used in a couple decades. Well, we bought some muriatic acid and pulled the tank. Oh, by the way, when I say WE I do mean the Wife and I. She is right there with gloves on and wrench in hand.
What we found in the tank was.... disappointing. We were able to pour out a nice pile of rust. When I say pile I mean a 6 inch tall pile of rust dust. We put some nuts/rocks we had inside the tank and decided to dance around with it like a couple of hippies on peyote. Trying to make sure we knocked any loose rust from every nook and cranny. When we dumped the nuts out we had another pile of rust nearly matching the first. Damn.
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In went the acid for a bath and then in again. We did three treatments until it was coming out nice and clear. We neutralized the acid with baking soda and started over again.

Now, with the aux tank working we wanted to go on another adventure. The process continues. The only way we feel motivated to work on stuff is to know that the carrot of an adventure is waiting at the end of our progress.
Being just a day run I didn't post it on Expo, but here it is: https://www.dirtsunrise.com/single-post/2017/02/15/A-three-hour-tour
We had a good time, but did much deeper water crossings that I'd planned for. Tonto took it all in stride!
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I don't have a picture of ol Tonto because the camera crew that follows me around doesn't exist, but this is the jeep behind us that I said, IT'S FINE, MY OLD TOYOTA MADE IT SO YOU SHOULD HAVE NO PROBLEM!!
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With the deep crossing done we enjoyed the rest of the mini crossing and reveled in how attached to this little truck we were becoming.

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SOAZ

Tim and Kelsey get lost..
Well, Tonto did so well on our day trip that I thought I'd double down and do a 3 day weekend in the truck. As my friend Dennis says, "What could go wrong?!"
Here's part 1 and 2.
https://www.dirtsunrise.com/single-post/2017/03/28/Going-Analog-12
https://www.dirtsunrise.com/single-post/2017/03/28/Going-Analog-22

...but of course I'm going to post a couple favorites from the long weekend here:


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Go little buddy goooo!
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bzzzzzzzzzzzzzzzzzzzzzzzzzzzzzzzzzzzzzzzzz (The Jetson's sound is in my head for this one)
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In summary, he did great. We brought plenty of carb cleaner and fuel filters in case there was any debris in the tanks, but nothing was needed. He slurped all 30 something gallons of fuel on the trip, but got us home safe and sound. It was a great idea... as opposed to if we broke down in the middle of nowhere far from help... then it would have been a bad... idea.
 

SOAZ

Tim and Kelsey get lost..
What's that? I don't have enough things to fix on old Tonto? Okay, let's add one more. We did a quickie drive to show some folks around after a cars and coffee and some yahoo in a golf cart (I think some people call them UTV's) ran into Tonto while we were sitting still.
I calmed the murderous rage and let the guy go on his way hoping natural selection would do the job for me.
https://www.dirtsunrise.com/single-post/2017/05/05/A-three-hour-tour

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We continued on and tried not to think about it... all I did was think about it and pretend to have fun.
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I drove across a section of the Verde River I knew was fairly shallow, but it sure looked impressive. Tonto said he was doing an impression of an island.

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Now... I had things to fix... Plenty of things to fix.
We headed to a buddys house a couple hours away to borrow his lift. Air tools and a lift, how do I manage without these wonderful toys!!??
Full write up of maint is here: https://www.dirtsunrise.com/single-post/2017/05/10/Take-a-knee-Rockford
Basically, we put him up on the lift at 8am and had finished rebuilding the front axle and welding his new boo boo by sun down. It was a hell of a day!

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It was a messy job.
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The most wonderful helper in all the land. Go Kelsey Go!
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Tonto just got a bit more hitch in his giddyup. It's nice to know the front axle and knuckles are happy for many miles yet to come.
He made the highway drive home in the summer heat no problem.

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SOAZ

Tim and Kelsey get lost..
After all of this work we thought it was only right to take Tonto to Overland Expo to show himself off. I've worked every Overland Expo since it started teaching classes of one sort or another so it was fun to use him in a few classes and see how he did.
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Here, Tonto looks away in disgust at the Land Rover that's trying to flirt with him while people learn about tires and such. Good Tonto.
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Here, Tonto stares off into the sunset unimpressed by some sort of camel trying to show off.

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SOAZ

Tim and Kelsey get lost..
For new years we decided to take Ol Tonto our exploring again. He needed hip/knee replacement which is common given his age so we made sure to tackle it before making him explore for so many miles.
https://overland.kinja.com/fun-with-the-family-for-the-holidays-1821133893

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The new Old Man Emu "heavy" springs were so immensely more comfy and compliant than the old clapped and rusted out springs that it felt like driving our 80 series. Okay, not really. Not even close, but it was a HUGE improvement!
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Good times for Christmas!
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All of that work and I only snapped off 1 of the grease zerk fittings. That has to be a record for me.

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As is tradition, we did some work, so we gotta go for a drive!

Found a new boat!
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We love the way the new springs ride and how the truck sits. A big thanks to Kurt at Cruiser Outfitters for the springs. (Not sponsored, just appreciate the time and info)
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SOAZ

Tim and Kelsey get lost..
All of that just about brings us current! We headed out for the long weekend in Tonto to explore from the California state line back to home (Phoenix) on dirt. It was fantastic. A hell of a workout too. Tonto has no power steering and I have no plans to add it.
Part 1-4 of the trip are here, but I also posted it in the forums here. I'm trying to get better at it!
https://www.dirtsunrise.com/single-post/2018/01/03/Keeping-it-simple-for-New-Years-Part-1
https://www.dirtsunrise.com/single-post/2018/01/04/KEEPING-IT-SIMPLE-FOR-NEW-YEARS-PART-2
https://www.dirtsunrise.com/single-post/2018/01/05/Keeping-it-simple-for-New-Years-Part-3
https://www.dirtsunrise.com/single-post/2018/01/08/Keeping-it-simple-for-New-Years-Part-4-The-end

Here are a few highlights:
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SOAZ

Tim and Kelsey get lost..
That just about brings us current. At the moment the only thing I didn't mention is that Kelsey replaced the window felts, driver side crank and seals so the windows no longer bounce around freely making me wonder what hit will shatter the glass. It's really nice to have working windows. It's the little things.

If you're more of a video person here is a random collection of Tonto's starring roles:
[video]https://youtu.be/20ILMuhgWSw[/video]

Maint weekend in Tucson:
[video]https://youtu.be/7gFvZHjqSZw[/video]

Another trip to Tucson:
https://youtu.be/HyjVQHDgGIU


HyjVQHDgGIU

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