1984 FJ40 Restoration

[nOmS6]

Dear All.. I am new here and am already impressed by the info available. Also pleased by the number of FJ40 enthusiasts wheeling around.
So.. I got me a 1984 FJ40 from an army auction in November 2010. I am working on it, that is, restoring it as I post this. Some really nice rigs I have seen on these forums and would like to share the progress of mine and invite comments/suggestions from experienced users.

This is how I found it at the auction

Removed the soft top hood, its support system and the rear seats before taking to the mechanic

My main goal is to get it mechanically sound first and as per stock as possible. So it went to the mechanic before the body shop. Here the engine is removed and being put in with new everything

Then came the dismantling part. Removed the gear box and front hubs so that new hubs with Disk Brakes and Manual Locking 4 by 4 hubs could be installed. The frame and the Engine compartment needed to be painted as well before the engine and transmission could be re-installed.

Here is the frame after initial paint

Manual Locking Hubs with Disk Brakes installed

Engine and Gear re-installed on the now painted frame. Not to forget a Power Steering Box as well

Since the above picture, suspension has been rebuilt - all tie-rod ends replaced, new tie-rod shock installed, rear wheel brake drums restored (new piston cylinders) and the rear differential has been over hauled (as it was jammed).

Now the rig is at the body shop. Waiting for the weather to clear up so that the beautification can start. I have decided on the Honda Metallic Steel Grey color for it.

Still to do after the paint job would be..
Steering pump install
A bigger radiator install
Single seats for front
Bull Bars
Soft Top
Alloys and tires
Air conditioning
and the list goes on..

Let me know what ya'all think..

[bboyxtacy]

nice to see the actual version of the jeep....it seems pretty intact though requires many alteration or refurbishing.....good luck bro....get it on wheels quickly so that we can smoke some on the ride towards Duddiput....

[tareen]

@nOmS6...Nice clean vehicle you got there and good going on the restoration.

I suggest move it to the following section to get the appreciation it deserves.
4X4 Clubs / Off Roaders / SUV - PakWheels Forums

Regards

[nOmS6]

@tareen... thanks.
how do i move the thread to that other forum? Do I need to repost it or just give a link? help appreciated!
regards.

[hanimughal]

seen ur jeep
good work goin ..
it was in really good shape.. ur fj's body was in really good condition..
best of luck..

[tamoorwazire]

sallam

Its a beauty

For how much you bought it and from where ?

Regards

[TLCFJ40]

best of luck bro u donner vehicle looks in a very good shape. Hoping for fantastic results.
regards

[machine]

Dear All.. I am new here and am already impressed by the info available. Also pleased by the number of FJ40 enthusiasts wheeling around.
So.. I got me a 1984 FJ40 from an army auction in November 2010. I am working on it, that is, restoring it as I post this. Some really nice rigs I have seen on these forums and would like to share the progress of mine and invite comments/suggestions from experienced users.

This is how I found it at the auction

Removed the soft top hood, its support system and the rear seats before taking to the mechanic

My main goal is to get it mechanically sound first and as per stock as possible. So it went to the mechanic before the body shop. Here the engine is removed and being put in with new everything

Then came the dismantling part. Removed the gear box and front hubs so that new hubs with Disk Brakes and Manual Locking 4 by 4 hubs could be installed. The frame and the Engine compartment needed to be painted as well before the engine and transmission could be re-installed.

Here is the frame after initial paint

Manual Locking Hubs with Disk Brakes installed

Engine and Gear re-installed on the now painted frame. Not to forget a Power Steering Box as well

Since the above picture, suspension has been rebuilt - all tie-rod ends replaced, new tie-rod shock installed, rear wheel brake drums restored (new piston cylinders) and the rear differential has been over hauled (as it was jammed).

Now the rig is at the body shop. Waiting for the weather to clear up so that the beautification can start. I have decided on the Honda Metallic Steel Grey color for it.

Still to do after the paint job would be..
Steering pump install
A bigger radiator install
Single seats for front
Bull Bars
Soft Top
Alloys and tires
Air conditioning
and the list goes on..

Let me know what ya'all think..

Bro - You get hold on a very clean piece... i have rarely seen this much clean TLC in auction with almost everything intact.

Congrats and post alot of pictures.... all thumbs up.....

[ANK]

hey....as everyone appreciated; i have the same comments. You got hold of an extreme good condition rig out of auction:).....will be waiting to see results and keep us updated

[nOmS6]

Thank you all for the lovely comments. me indeed very lucky to have found such a clean one. the more we took it apart the more it amazed us. Reckon it might was used by some officer himself.

Am gonna collect some fresh pictures today at the paint shop. Will post them in the evening Inshallah.

regards

[hasan.nqv]

i appreciate ur hardwork in restoring this jeep in original specs....KEEP IT UP SIR

eager to see more pics soon =)

[tayyabbaig]

MashAllah u've got it in really nice condition bro. Very good work going. Waiting to see the final results. All the best.

[nOmS6]

Got some more pics today from the paint job goin on..

This is the front seat which will be going in replacing the bench type originals. These are from 94 Model LC Prado.

Got them from Bilal Gunj.. very dirty at the moment. But I'm gonna get them upholstered in leather once their fitting is finalized. So not getting them washed for now.

and here are some pics from the ongoing paint 'tayyari'..

Here is a view of the finished base of the body. Pic taken from the rear looking up at the floor. The rear differential is showing.

The engine compartment front shield has also been finished since it would be hard to paint later when the body is bolted on to the frame. The engine is ready and in already !

A Closer look to get the idea of the final color

That's all for now folks.. Paint is expected to finish in a weeks time.. yea I know, "expected"..
Anyways, will post the finished paint jobs pics next..

Thanks all for viewing..

regards,

[machine]

Thats a great color - However if i would have a choice, i would have gone for pearl white color.

[sarmadqureshi]

What's the cost to completely overhaul a 2F engine ? I mean everything new and has that been the way most people have done it here ?
or is it sufficient to get new rings only ?

[baburawan]

good work done.. how much time it will take to run..

[juadjee]

You took us through most of the restoration process in just ONE post. I am impressed! And that is a stunning vehicle you're restoring. For the benefit of us members, would you mind sharing the costs associated with your restoration job?

[nOmS6]

@SarmadQureshi: Engine overhauling costs are dependent on that particular engines requirements, I think. Some might be ok with just rings replacement and some might need more. Also I think it depends on the user as well. To get it running is one thing and to get it sailing smooth and shining is another. In my case, the pistons need to be replaced. So instead of getting the block bored for bigger pistons, I changed the sleeves and restored it to the original factory sizes. Like the mechanics say "zero ki setting". The crank was not tooled before so it was turned and would do ok. Mains and biggens were replaced. Valves, valve guides were replaced. Clutch pressure plate and other clutch assembly other than the fly wheel was also replaced with new parts. Some bolts and seals were missing so I replaced all the bolts with new 'japani' bolts after getting them nickled. Got the engine head nickled. air intakes were polished as well. I have not totalled what the engine restoration alone has cost me yet. Once it will be running as per my liking than I would be glad to give a cost break down.

@BabarAwan: Bro.. honestly, my patience is being tested at this stage. 2 months after the start of this project, all but a couple of minor mechanical work already being complete, its frustrating waiting for the paint job to finish. We took the vehicle as much apart as possible. And preparing/painting each part individually so taking a lot longer. Latest "estimates" are another fortnight before it will be ready for the first test run. Getting roll bars and soft top, alloys and tyres is after that. Interior upgradation will be an ongoing process, as it seems.

@Juadjee: I saved the details for the more inquisitive. I have all the bills filed. Would love to share the costs. Let it be running first. will give a complete cost break up for sure.

[speedster_101]

Its good that you are restoring it to stock vehicle.
Best of luck for complete restoration.

[juadjee]

@Juadjee: I saved the details for the more inquisitive. I have all the bills filed. Would love to share the costs. Let it be running first. will give a complete cost break up for sure.

Sure, I'm subscribed to your thread now and will be following updates as you post them. You've got an inquisitive member here :D. I must say, i like the attention to detail and doing things 'properly' as you are. God Speed!