Topic: 1982 SR5 Longbed

[Toyotadon]

Continuing on for the next couple nights, we made some more progress.

https://www.youtube.com/watch?v=-Mh0La3mZpU

https://www.youtube.com/watch?v=gwnHbQiCTZg

Pulling the shifters out.

https://www.youtube.com/watch?v=2NHeIlez3gg

https://www.youtube.com/watch?v=MGHos830cnw

Transfer shifter.

https://www.youtube.com/watch?v=kaTBXoOLVLU

My photographer didn't get the camera set up for video in time, so we didn't document the trans & transfer removal, but it went pretty well just balanced on a floor jack.





The oil leak accumulation can be seen on the back of the engine.

[Toyotadon [OP]]

Thursday evening after work, I took a run up to Fresno with the whole chunk loaded in the back of my Camry.  Marlin was waiting for me, and in his usual helpful way, spent more time going over it than he would ever charge for.  We started with throwing the clutch, flywheel, & pressure plate in his parts washer, then got the transmission & transfer case up on the bench.

After looking at the serial numbers, it appears that the transmission was swapped at some point.  My truck was built February 1982, the transfer case is the same, but the trans has a date of November 1981.  Pulling the top cover & nosecone confirmed that I have the earlier, small-case L50, so that was a letdown. 

Marlin sold me on upgrading to the larger front bearing and we talked about the center bearing and fifth gear a little bit.  Fortunately, after splitting the transfer case from the trans, we found that fifth gear has already been upgraded.  Marlin commented that whoever built it actually knew a little bit of what they were doing.  He will make his own improvements to things like the shift forks, rebuild the whole thing, and hopefully get some 4.70 gears into the transfer case.

With the clutch & pressure plate cleaned up, it looks like I will be reusing them.  Marlin also machined my flywheel to spec, and signed it for me (so thankful I thought to bring those along).

[Toyotadon [OP]]

A little bit of inspecting the leak(s).

https://youtu.be/m2LyEpFnkRY

https://youtu.be/rPWdJBWLh7I

Pulled the radiator and took it into the shop.  They called me the next day and said it's not repairable.



It's leaking from the core, and with the price of metal, a new core would be over $500.

I've also been working at getting the P/S pump out.  The pressure hose is giving me trouble.

[redneckcustoms13]

Go with an all aluminum radiator, like 150 on ebay. What's up with the pressure line?

[Toyotadon [OP]]

I actually can get a brass and copper radiator from Napa for ~$125 with a discount, so will likely do that.  The pressure line is just very tight, I need to try it with the best line wrench I can find.

[Toyotadon [OP]]

I checked with all the older techs at work and none of them had a 17mm line wrench.  One of them had a pair of long pliers he said works well on things like that, and a cheater pipe to slide over the handle, which I brought home tonight.

I ended up finding another line wrench in the toolbox that I have in my Cruiser.  It's an S-K brand, but fit tighter and had more bulk around the head than my Mac.  Using it with the cheater pipe and holding the outlet with a 1 1/16" open end, it popped loose.



Someone had used a pair of pliers on it before, as evidenced by the scars, but it's still usable.

[Toyotadon [OP]]

I also meant to mention that wrench was given to me by my brother-in-law, who is a luthier (violin-maker).  He and a friend bought a "lot" of toolboxes full of tools at auction.  They thought they were bidding on just one, but got all of them at a bargain, then had to haul them off.  I think they each kept one box, sold the rest for a profit, then had were a few tools left over that I got.

[83 yoter]

Looks like you're having fun now! Nice find by the way, it's getting a lot harder to find 1st gens in that kind of shape. Have you decided on whether you're going to keep the 22r or do a 22re swap? I'm also thinking about doing the re swap on my '83.

[Toyotadon [OP]]

At this point I'm still keeping what I have.  I've been thinking I should total up the polls from this thread and the one on IH8MUD, so we can all see the totals.

[Toyotadon [OP]]

So I put together the two polls that I ran on Marlin & IH8MUD forums, and these are the results:

Full restoration to factory original condition Received 4 votes total.

Resto-mod with a newer FI engine, like the 22RE or 2RZ/3RZ Received 13 votes total, this being the favorite of the Marlin folks.

Crawler build with tons, big block, and exocage! Received 0 votes total. I guess no one wanted to go along with the joke.

"Driver-quality" restoration, leaving a lot of the paint/patina as-is & enjoying it Received 15 votes total, edging out the Resto-mod by a scant 13 1/3 percent.

Which direction should I go with this build?
Edit
Poll closed Jun 29, 2015.

    Full restoration to factory original condition
    2 vote(s)
    11.1%
    Resto-mod with a newer FI engine, like the 22RE or 2RZ/3RZ
    4 vote(s)
    22.2%
    Crawler build with tons, big block, and exocage!
    0 vote(s)
    0.0%
    *
    "Driver-quality" restoration, leaving a lot of the paint/patina as-is & enjoying it
    12 vote(s)
    66.7%

Which direction should I go with this build?

Full restoration to factory original condition
        2 (14.3%)

Resto-mod with a newer FI engine, like the 22RE or 2RZ/3RZ
    9 (64.3%)

Crawler build with tons, big block, and exocage!
    0 (0%)

"Driver-quality" restoration, leaving a lot of the paint & patina as-is, cleaning & fixing the interior & wiring, and just enjoying it for awhile.
    3 (21.4%)

Total Members Voted: 14

Voting closed: Jun 29, 2015, 01:40:21 PM

[Toyotadon [OP]]

A lot of the work right now is cleaning parts; either nuts & bolts for reassembly time, or parts that are having paint/rust removed and repainted.





Here's the power steering pump rebuild progress so far.







Getting the front seal out was quite a chore, but once started, it had to be done.  The repair manual actually says to cut the rubber of the seal from around the shaft, then pry the rest out.





Under the seal is a snap ring, which I had to remove with a couple screwdrivers, since my snap ring pliers were at work.



Most of these pictures I took for my own benefit when reassembling.



We were doing this in the back of the truck, had the FSM on the iPad, and other parts stashed all around.



Everything was still available from Toyota, including o-rings, gaskets, etc. just not in kit form anymore.  Of course, the bushing inside the housing has never been available separately, and mine shows some wear (too hard to photograph), but I will just have to run with it.

[Toyotadon [OP]]

I also have the rear main seal housing cleaned & prepped for reassembly.





New seal installed.



The EGR Cooler mounts to the back of the cylinder head, and seemed to be the source of one of my leaks.



It allows exhaust gasses to pass next to the coolant passage before entering the combustion chamber.  Both portions need to be sealed properly, and Marlin gave me a recommendation for improving the coolant portion.



Many of the water pumps on newer Toyota vehicles have similar grooves for the FIPG to seal into, so it should help here as well.

Back to some of the painting--I am trying the Rust-Oleum high temp primer and engine enamel, which is turning out really nice.



I need to get another picture of the transfer case shifter after paint, but it makes me want to wet sand it and add more coats.

[cali4runner]

@toyotadon where did you find those heat shield insulators?? i need to install my heat shield to pass smog

[redneckcustoms13]

Dealership sells them. As well as some aftermarket engine gasket kits come with them. I have a set if your interested pm me.

[Toyotadon [OP]]

I will have to find out if they are still available from Toyota or otherwise.  Mine were in the toolbox of a friend/coworker.

[cali4runner]

alright thanks guys

[tgmaul88]

I like

[Toyotadon [OP]]

Thanks for the bump, reminding me I need to update this.

The prep job on the fan shroud didn't turn out, and the primer started peeling.



I ended up redoing it with the 3M plastic bristle tool, and the results (no pic yet) were much better.



Also finished getting the power steering pump back together...



...and installed.



The formed reservoir hose is not available, but a standard hose cut to length works fine.

[Toyotadon [OP]]

I did some work on a guy's FJ Cruiser, and he has a bead blaster sitting in his garage.  He normally uses it for refinishing firearms as a side hobby, but was kind enough to clean up a couple of my parts.



This is much better than the wire wheel and sandpaper I was using.



The inside of the oil pan still has some rust, so I went ahead and oiled it when I was priming and painting.





Just one fuzzy picture of it piled in the back of the truck with everything else.

[Toyotadon [OP]]

I got the trans back from Marlin.



Here's my 16 month old "helping" in the garage.  He actually already knows how a screwdriver works.



So, on my day off this week, I decided to try to get everything else back together as well.

First, i finished cleaning up the back of the head.



Then, I got the plate ready for install. I used FIPG for oil around the EGR ports, and the green tube is what Toyota uses with the newer coolants.





Installed!  The sealant oozed out a bit and looks messy, but it should hold. I was also concerned about the cam plug possibly leaking, so added some sealant under its flap.

[Toyotadon [OP]]

That was about all I accomplished on my day off, because the bolts for the rear main seal retainer went missing. Today I scavenged some from around the shop and brought them home, with just enough time before dinner to install the retainer & the oil pan.









Those are Fleet Runner belts that Napa gets from Gates. All except the narrow one.

[redneckcustoms13]

Man I love this truck.

[toyotech]

Nice work so far.

[Plainview]

Really like this project!  You scored on this truck, they go for way more than that around here.

Keep up the good work!   

[Toyotadon [OP]]

So, what does this mean?



Yep, it's back in, thanks to the 3 day weekend!





Except I had the transfer case shifter in backwards. Here it is the right way, with a new boot from this guy: http://www.yotatech.com/f109/new-handmade-replica-shifter-boots-sale-286513/



One thing I was also needing to do was address the "dying at times" issue. Awhile back, I found this thread about the ECM connections: http://board.marlincrawler.com/index.php?topic=95111

So, while I was addressing other things, I also did this.

[Toyotadon [OP]]

I got the u-joints done on the rear driveshaft and painted it all up.



Then on 7/10/16 at 7:00 PM, it pulled out of the garage under its own power.

Still working on the front driveshaft, and having a few issues.  Some parts are all nicely painted.





Others I'm still working on.



The plug for the sliding portion of the shaft was missing.  I had a newer shaft that I popped the plug out of, but it was slightly larger diameter.  I used the bench grinder with a pocket magnet holding the plug.



It fit almost perfectly, with a little bit of FIPG to seal it up and a restake to hold it in place.



Also working on the CV ball joint that goes in the middle of the double cardan joint.  I tried to get it out with the seal puller and a hammer.





The seal popped out, but the joint stayed in until I got a small Torx bit to put in the grease hole, and used the press.



That actually only got the ball out, then I had to use the puller on the race.  Using the kit from Precision (613) that it calls for, but the new seal is a smaller diameter.  Found out these kits all come from Rockford Driveline, and they have an adapter ring that it looks like I need. http://www.rockforddriveline.com/toyota.pdf  I called them, got great customer service, and now one is on its way.

[green200b]

I love what you're doing with this. Somewhere nearish me there is a '79 that has had a concourse restoration, which is cool, but I like that this is staying unrestored. Looking forward to more updates

[:)bestgen4runner]

Hey, 
I wanted to give you a heads up. This plate is for the Egr system. E for exhaust. (hot) 
Fipg alone will not seal this area.  There is an exhaust gasket that goes in this location. 
I have had to reseal this plate on a vehicle that had used Fipg only.  It is very difficult to remove with the engine in the truck. 
I encourage you to use the exhaust gasket that is designed for this location to avoid future problems.   

[Toyotadon [OP]]

Thanks for the heads up.  I had checked in the Toyota parts system and found the gasket was not available.  Marlin was the one who told me he's had success with FIPG, but I may need to look at the aftermarket for a gasket.

[:)bestgen4runner]

I can get you the correct part # 
Its still available from Toyota.