project40

I. Introduction: My FJ40 is in a reasonable good shape. Cosmetically, there is almost no rust and fortunately all these little rusts are just very minor surface rust, the paint is still very good, all it needs is some serious deep cleanning and waxing. Mechanically, I beleive the 2F engine has been rebuilt by the original owner, engine compression is around 144 to 150 psi for all 6 cylinders. But it still needs works in other areas that previous owners have neglected. Also there is no bondo on the truck!

II. Objectives: Even my rig is road worthy but it can be better so the objective is to get rig ready for Summer 99. I beleive in Toyota engineering/quality and I am not interested in a full-blown hard core trail rig therefore I will not re-engineering the truck by convert to Chevy 350 engine, spring-over, shacke-reversal,... and will use as much Toyota parts as I can (i.e. truely "Powered by Toyota"). Mechanically, the truck will be reliable enough to travel up to 2000 miles and capable of handle "4 rated" trails. Cosmetically, it will retain much of its rugged original classic look i.e. no additional chromes, no diamond plates, no flashy paint job or alloy wheels....

III. Strategy: Originally, when I bought the truck, I planned to take time (4-5 years) to finish but after seeing so many Toyota Land Cruiser listers having fun with their rigs I just have to speed up a bit to do some offroading soon, currently the strategy is to fix up the most important things first and minor later and while one task(s) is going I also gather parts and tools for next tasks. Mulitple related tasks are grouped together to be executed at the same time. Questionable 25-year-old vital parts will be replaced preemtively and used as spares.

IV. Requirements: Time: I also love mountain biking which needs regular time on the bike otherwise I will be the last in the pack climbing that steep hill (ain't fun) or worse pushing up the bike while I should just simply ride up. Therefore I need to allocate time fairly between working on the rig and biking. Money: Always a major factor, I beleive in quality parts and of course they're pretty expensive. Good tools are not cheap neither...

V. Schedule: First offoad: Summer 2000! And Rubithon 2001!! And Moab 2002!!!

VI. Risks and Contingency: Can't take a hobby too serious, you know :-).

VII. Task itemizations: Here we go....

Task No. Task Descriptions Status

1. Replaced new Toyota Shifter ball, part from Cool Cruiser Of Texas Done

2. Installed new Toyota passenger side rear mirror, part from Spector Off Road Done

3. Installed new Toyota passenger side rear conner reflector, part from CCOT Done

4. Replaced new Toyota shifter instruction plate on the glove box, part from Scott Tate Done

5. Installed new NGK spark plugs, part from Kragen Done

6. Installed new distributor cap with Toyota points and condensor for Toyota distributor, parts from MAF Done

7. Installed new Toyota ignition wires, parts from Stevens Creek Toyota Done

8. Installed new Toyota PCV valve, part from Stevens Creek Toyota Done

9. New OME suspensions system: 4 OME springs, 4 OME shocks, 8 OME U-bolts, 4 OME extended shackles, 4 OME bushing kits, 4 Spector Off-Road u-bolt skid plates, 4 TPI greasable frame pins, 8 Toyota frame-pin screws. Most OME parts were purchased from 4Wheel-Part-Wholesaler, stock frame-pin screws bought from SOR. Done!

10. Replaced stock steering stabilizer with OME stabilizer. Notes: Task no. 10, 11, 12, 13, 14 and 15 were executed concurrently. Parts came from 4Wheel-Part-Wholesaler. Done!

11. Rebuilt steering arm center - with rebuild kit from MAN-A-FRE Done!

12. Rebuilt front end - task included replacing new knuckle bearings; inner/outer wheel bearings, seals and gaskets. The rebuild kits came from TPI (all bearing are Koyo bearings, new gaskets, felts, axle seals,..) Done!

13. Rebuilt steering system - Replaced all tie-rod ends and rods with Toyota tie-rod ends and rods parts bought from Scott Tate of Sterling Lexus. Done!

14. Replaced the original Warn Lock-O-Matic hub with brand new Warn Premium locking hubs bought from NorCal swap meet with all new hub bolts. This task was completed as the same time as task#12 Done!

15. New rebuilt air pump Done!

16. Rebuilt brake system - including new Toyota brake booster, new Toyota master cylinder, new (4) Toyota drums, new (8) Toyota brake shoes, new Toyota flexible (2) hoses, new stainless steel MAF DOT approved front and rear flexible brake hoses, All new Toyota (8) brake wheel cylinders. Most other parts came from the local Stevens Creek Toyota. Brake booster and master cylinder both came from Scott Tate of Sterling Lexus. Notes: Toyota parts are more expensive but last much longer and safety comes first! Done!

17. Fix the exhaust leak, new Toyota manifold gasket/bolts/studs/nuts, have the manifold planned by machine shop if needed. All parts came from Stevens Creek Toyota . I have no exhaust leak after testing/checking. Parts saved! Done!

18. New exhaust system - 2.25" Aluminized pipes with Turbo Flow Master Done!

19. New Toyota carburator and Toyota fuel filter. Carb bought from SOR, fuel filter bought from Stevens Creek Toyota Done

20. 5 Superior 15x8 White Spoke Superstar wheels with 33x12.5 BFGoodrich Mud Terrain's. Tires bought from Price Club, wheels bought from American Tires in San Jose. Done!

21. New Toyota brake and clutch pedal pads from SOR Done!

22. New front seat and rear jump seat upholsery, parts came from Spector Offroad, the style is identical to stock Done!

23. Replaced the current chipped and cracked steering wheel with a great condition steering wheel bought from a TLCA lister Done!

24. Replaced the the new Toyota gas cap, gas cap bought from Stevens Creek Toyota Done

25. New cooling system: new Toyota water pumps, new Toyota thermostat, new Toyota radiator. The hoses bought from Cool Cruiser of Texas. New Toyota belts. Toyota parts came from Stevens Creek Toyota and Scott Tates of Sterling McCall Toyota. Done

26. Touch up the paint where neeeded. Waxing and buffing Not yet

27. Original '63 Headlight bezel bought from a local lister. This bezel is quite rare that I thought I couldn't find one. Done

28. Repaint the fiberclass roof cap. New aftermarket roof cap weather stripping and head liner from CCoT. Not Yet

29. Repaint radiator shield and install new radiator Toyota emblem. Emblem bought from Scott Tates Done

30. Try to get the fog out of the windshield replace if needed. Bought new OEM tinted windshield at Stevens Creek Toyota. I decided to keep the original windshield and sold the new OEM one to Jim Miller Done

31. New 3-point seat belts from CCOT Done!

32. Used but perfect condition dash pad boght from Bruce Lutz (LCML lister) Done!

33 New Toyota sun visors Done!

34. Safari roof rack - Heavy Duty roof rack bought from SOR Done!

35. Hella 4000 Offroad light kit and Hella 1000 Offroad light kit. Lights to be mounted on the roof rack. Lights bought from LCC, a total of 4 offroad lights and 2 separate light relays and wiring harnesses Done!

36. WARN 8274-50 Winch from Clemson 4 Wheel Done!

37. New OEM slave clutch cylinder and OEM flexible clutch hose - both bought from Stevens Creek Toyota.
To be installed at the same time as task #52 (New clutch works). Done!

39. Hella H4 55/60 replacement headlamps. Light bought at Local 4wheel-parts-wholeseller Done!

40.a Traction aiding devices / Differential rebuilds - Install ARB Air Lockers front and rear, and rebuild the front and rear differentials at the same time! Differentials rebuilt kits contain carrier and pinion bearings/races, pinion nuts and pinion seals. ARB lockers came from TPI, rebuilt kits came from MAF - all bearing are Koyo's. Since the installation of lockers requires expensive tools for pretty much a single usage, I sourced out the installations to Rear End Specialty in Santa Clara, California and saved money by removed and installed the third members myself. Futhermore I also install the air compressor and do electrical wirings and air line routings. Note: when installing the air locker into the rear differential, I realized that new ring and pinion are needed (that explained the howling in the rear end) therefore I bought new Precision Gears ring and pinion from Reider Racing, I also bought the mini installation kit for this rear end from the same vendor. Since Precision Gears pinion has fine spline I had to replace the flange with a new Toyota fine spline flange bought from Scott Tate at Jay Marks Toyota. The complete rebuild and upgrade of the differentials with ARB air lockers has unexpectedly costed me soooo much. Done! Both
front and rear.

40.b On Board air - Install the ARB air compressor Done!

41. Toyota mini-truck power steering, parts included:
- JTO mini-truck PS gear box bracket.
- JTO saginaw pump bracket, looks just like the BTB bracket..
- JT0 custom high pressure hose..
- Rebuilt '75 Chevy V8 truck saginaw pump.
- '79-'84 used mini-truck gear box.
- IFS mini-truck PS cooler and returned barb from junk yard.
- Early 80's Volvo wide pulley for the sagnaw pump from junk yard,
- Returned hose and stainless steel clampsfrom Napa.
- Grade 8 nuts/bolts/washersfrom Orchard Supplies Hardware.
- New longer belt at Kragen.
- ATF Fluids. Done

42. Transmission gear reduction / H41 tranny - Replace stock 4speed transmission with non-USA Toyota Land Cruiser compound low 4 speed tranny (first gear ratio is 4.93) from SOR. Notes: the compound low tranny and 3 speed transfer case will be installed at the same time. New tranny gasket kit was bought from Stevens Creek Toyota. Done!

43. Transfer case gear reduction / J30 transfer case rebuild - Replace stock 4speed transfercase with late 3 speed transfer case (low gear ratio is 2.31), transfer case to be rebuilt before matching to non-USA tranny. Notes: I bought an used '73 transfercase from PMC swap meet and a new '74 (transition year) input gear from Scott Tates at Jay Marks Toyota to match this 3speed transfer case to the 4speed non-USA transmission, I also replaced the high speed gear and idle gear cluster with new gears from Spector Off-Road .Transfer case rebuild kit bought from MAF, the kit has all Koyo bearings, seals, gaskets, idle gear shaft pin, nuts, boots and other small parts. The special replacement Datsun B210 rear axle bearing was bought from Fremont Nissan (if you ever wonder, the bearing is made in Japan by NSK). I also bought 2 spacers for the input shaft from Warden's Automotives. Done!

~~43.~~ ~~Marlin Crawler gears/transfercase when available~~. *** Marlin no longer makes LC crawler gear

44. New electricals - Dual Optima red top batteries with stock high output (80amps) alternator and battery isolator. 2 Optima redtop batteries came from Oakland 4Wheel Parts Wholesaller during yearly sale every March. Stock High Output alternator came from MAF. Voltage regulator came from Sterling Toyota. Warn isolator bought from 4Wheel-parts-wholeseller.
New longer 1-guage battery cables. (4) new Military spec'ed battery terminals. Done!

45. Toyota Torque Reduction starter from Stevens Creek Toyota Done!

46. Man-a-fre rear fender flares, it's going to be very tough to cut those perfect rear fenders :-( Parts
acquired

47. New trail communication gears - Cobra 18UWB CB and Firestik II Antenna Kit. CB bought directly from Cobra, antenna kit (which includes 4' Firestik antenna, mount, 18' wire, stainless spring, connector, CB hanger) bought from Fry's Electornics Done!

48. New stereo system - Bazooka 8" subwoofer came from The Good Guys. Sony CD player with 40wattsX4 output. CD player bought from Fry's Electronics. Bose 101 Environmental speakers bought from Fry's Electronics. Done!

49 Semi-floating axle - Rear end rebuild - Replaced rear inner axle seals and rear wheel bearingss. Task was done at the same time as Task 40. Seals and gaskets were Toyota ones. Toyota seals bought from Sterling McCall Toyota, bearings bought from Stevens Creek Toyota (this axle housing and axle shafts were later sold to Morgan Fletcher because of later full floating axle swap) Done!

50. Rebuild ignition system - Pertronix Ignitor (partno. 1665) and Frame Thrower Epoxy 40,000 volt coil came from Northern Auto Parts, MSD 6-Offroading Ignition control which was bought from Summit Racings. Done!

51. Hi-Lift 48" Casting Jack and Hi-Lift tower mount (4" high). The jack bought from a local new 4x4 shop in Fremont. Done!

52. New clutch works - to be done at the same time as task#41 and #42. This includes new clutch, pressure plate, throw out bearing, pilot bearing and rear main seal. All new (no remanufactured) parts bought from Stevens Creek Toyota. Done!

53. New bumper - MAF 4+ Plus Bull Bar with Warn 8274 mount including stainless mounting nuts/washers/bolts Done!

54. New Confer rear lense protectors bought from Bruce Lutz Done!

55. Confer gas can holder bought from Bruce Lutz Done

56. New custom Butch Built dual optima battery tray be installed the same time as task#44 Done!

57. New "Toyota Land Cruiser" side hood emblems Done!

58. New front hood to bib bumpers and hood to side fender bumpers Done!

59. Replaced the 2 screws in front of gauge cluster with new stock screws Done

60. Revovery gears - 30' recovery strap and ARB snatch block bought from LCC Done

61. ARB air hose kit - bought from LCC Done

62. 5-gallon Bliz gas can bought from 4wheel-parts-wholesaller Done

63. Confer gas can holder mount bought from 4wheel-parts-wholesaller Done

64. New clutch hydraulic - New OEM clutch master cylinder and new OEM clutch slave cylinder and new OEM flexible clutch hose. Clutch slave and hose bought from Stevens Creek Toyota, Clutch master bought from JTOutffiters Done!

65. New Energy Suspension polyurethane body mount kit, kit bought from JTOutfitters kit acquired

66. Rear full-floating axle swap - Rear end rebuild - I acquired a non-usa/Autralian FJ40/45 full floating axle and swapped the stock semi-floating axle for this FF axle. The axle was rebuilt with new Timken bearings and Toyota seals and gaskets before being swapped in. Done!

67. Installed the extended OEM axle breathers and new rubber lines Done!

68. Installed new OEM mechanical fuel pump. Pump from Ebay Done!

69. Installed Northen Tools rear pintle hook Done

70. Installed new OEM oil pan gasket. Gasket from Ebay Done!

71. Installed new OEM valve cover gasket. Gasket from Stevens Creek Toyota Done!

72. Adjusted the valves according to specs Done!

73. Original tailgate from soft top fj40. Dave Tay found this tailgate for me. It came a guy in L.A. I looked for this tailgate for the past 3 years. To complete everything I bought 2 hooks and one latch from Stevens Creek Toyota Tailgate
bought!

76. Polished the 2F valve cover and dressed it up with the OEM "2F" sticker from SOR Done!

77. Strip and repaint the air filter unit also dress it up with OEM air filter sticker from SOR Done!

78. Auxillary Gas tank - Parts included:
- Confer Aux gas tank with skid plate kit bought from TPI (thanks to Joe Turpin of JTOuffiters who pointed out that TPI has the very last (discountinued) gas tank and the kit was deeply discounted.
- Early OEM gas sender and gasket bought from Stevens Creek Toyota.
- OEM gas cap bought from Stevens Creek Toyota
- 6-port selector valve bought from JCWhitney.com
- Roderick T. Daebelliehn sold me a complete OEM filler neck/gas door/backing plate cut out of a rusted out '74 FJ40 Done!

79. Rocker Sliders - Luke Porter at 4x4 Labs custom made a set of rocker slidesr that hide underneath the stock rockers and running boards, the sliders saved my rockers/running boards at Rubicon. Done!

80. High Clearance Rear bumper - Luke Porter custom made this baby. Done!

81. Interiror Liner X - have the interial proffessional liner Not Yet

82. Undercoat the tube with ruberized paint Not Yet

83. Repaint the truck professionally Not Yet

84. Mini-truck diskbrake conversion:
- New Timken wheel bearings and new seal/gasket kits.
- New Aisin locking hubs (OEM)
- New Downey flexible brake lines to the calipers
- Rebuilt calipers from Autozone
- New disk rotors
- Longfield birfields In Progress

85. Rubicon damage repair - my truck was damaged after the expensive Rubithon 2001 trip, here is a list of repair:

New front driver side OME spring: I bent this spring. Ouch! Thanks Alan Wesley

New rear passenger side OME spring: I bent this one too. Ouch! Ouch! Thanks again Alan

All new anti-inversion OME shackles to help prevent the above bent springs in the futrue

2 new BFG MT tires: thanked to Cosco Harzard Replacement - got two new free tires

New Conferr Bull Dog clamps to replace the Wilderness HD clamps which were not strong enough

New Toyota OEM driver side fender

Cut couple feet of the winch cable and had new loop made by proffessional shop

New front drive shaft to replaced the twisted one - Thanks Jimmy Miller

Done!

VIII. Technical advises: A bit more than a year ago, all I could do to my cars/trucks were washed them, changed oil, changed spark plugs... But thank to the Land Cruiser mail list, I have learned so much technically about the FJ40 to undertake this major project, to me it is simple as: no LCML no Project40 . Great bunch of off-roaders to hang around too.

IX. Techinal documentation references: These are the bibles:

Factory Toyota 2F engine manual - it came with the truck thank to the previous owner, can be ordered from Toyota dealers, factory manuals are must have for me.
Factory Toyota FJ40 Chassis manual - same as the above.
Factory Toyota '75 California Specification FJ40 Emission manual - bought from SOR
Gegory manual for Toyota Land Cruisers - Henry Brimmer got these treasures from Australia, a must have for me!
The Automotive Repair Book - An old text book published in '77 for "serious amateur", got this book from Dad.
Haynes Toyota Land Cruiser manual - Nice to have around but I don't use it often.

X. Parts and services providers: It's impossible to go through such a significant project without acknowledge these guys but look at it the other way: I spent serious hard earned bucks there too. I will keep the list update as more parts are bought:

Cool Cruisers of Texas: has one the best customer services! Chad is a very nice part guy.
Specter Off-Road: Good parts sellections but WATCH THEIR SHIPPING CHARGES!!! They make you pay 5 bucks for a box. For Toyota parts, I saved money buying parts from Stevens Creek Toyota because Spector is selling Toyota parts at retailed prices plus the high cost of shipping and handling not to mention that some of the parts that Spector is selling can be found at local NAPA....
Man-A-Fre: Has some aftermarket parts, I use them as the last resource, many listers had tough luck with MAF.
Stevens Creek Toyota: Local Toyota dealer - has some helpful part guys (not the gals) and 25% discount on ONLY 4x4 parts.
Sterling McCall Toyota: Scott Tates used to work here l, I love the 25% discount on parts.
Jay Marks Toyota: Scott Tates is a good guy and offers 25% discount on parts too.
TPI: so-so part selections, no big deals.
Clamson 4Wheel:Thanks to a TLC mail lister who pointed out this place with best price on Warn 8274-50!
4 Wheel Parts Wholesalers: Where I got the best deals on OME suspension system and Optima batteries.
Rear End Specialty in Santa Clara, California - Killer installation prices on ARB lockers and know what they're doing! Thanks Eric.
Northern Auto Parts: Good prices on Pertronic Ignitor and Frame Thrower coil - quick delivery
Summit Racing Equipment: Best price and quick delivery on MSD 6 ignition stuff. Milton Mui pointed out this place. Thanks.
America's Tire Co.: Local tire shop that carries Superior wheels, left "Discounted Tires" in the dust in services and pricing!
Reider Racing: Where I bought the Precision Gears ring and pinion. Lowest price found here!
Warden's Automotive: I bought 2 spacers for the 4-speed to 3-speed tranfer case swap
LCC: Where I bought the recovery/ARB air kits/Hella Off-road lights. One of the Hella stone shields is damaged and UPS didn't want to take care of it. The shield only cost couple bucks no big deal.
JT Outfitters: Joe Turpin is pretty cool guy, gave me a clutch aligment tool out of his tool box. He has best prices on OEM clutch parts and body mount kit. Looking forward to do more bussiness with JTO
Luke Porter at 4x4Labs.com: a young awsome fabricator who custom make my rocker slider and rear bumper

XI. Cruiserheads that saved my wrenching days: These are great people that I am fortunate to know, they went to great distance to help. Thanks very much!

John Kuhry: Local cruiserheads, helped me with so many things, he gave me a spare tire, moved my FF axle,..,..,..,.., keep up the good job :-)
Dave Tay: another local cruiser head, helped bought the Timken bearings, help moved the mini-truck front and other things in the future :-)
Simon Liew: Canadian lister who helped purchase Toyota parts that were imposible to get in the USA.
Charles Glabe for giving me a custom made (by himself) a mini-truck power steering pump bracket.
Eric Blase for helping to purchase the non-USA FJ40 full floating rear axle in Australia.
Dave Stedman for advices, cool Japanese stickers, and cruiser magazines.
Tony Tweedy for giving me a coil bracket.
Alan Wesley for the OME stuffs to fix the Rubicon damages
Roderick T. Daebelliehn for getting me that hard to find 75 fuel filler parts (for aux gas tank).
And may others that I forgot

XII. Post-mortem: Here are some stuffs I have learned:

Safety comes first when working on my truck and I would not compromise part quality on brakes, steering, and suspension.
My uncle is a very detail-oriented person when working on my truck, since I decided to keep the truck for life, I really took the time to each task carefully and paid attention to small details, therefore the end results were more satisfying.
"Pay peanuts got monkey" this concept applied pretty well to parts, after only one incident, I smartened up and go with Toyota parts as much I as can.
The above concepts also applied for tools.
Plan ahead with the upgrade so I would not buy part then later find out that I don't need it, thus saved money.
Don't buy parts 3 months before actual usage, it's too late to return/exchange the wrong parts.
There are vendors that sell the same parts for different prices, shop around and save.
Buy the parts locally if possible if they're a bit more expensive. Handle mail order damage parts is just too much.
LCML archives have most of the answers for all of the questions.
Take time and enjoy the wrenching....

Task No.	Task Descriptions	Status
1.	Replaced new Toyota Shifter ball, part from Cool Cruiser Of Texas	Done
2.	Installed new Toyota passenger side rear mirror, part from Spector Off Road	Done
3.	Installed new Toyota passenger side rear conner reflector, part from CCOT	Done
4.	Replaced new Toyota shifter instruction plate on the glove box, part from Scott Tate	Done
5.	Installed new NGK spark plugs, part from Kragen	Done
6.	Installed new distributor cap with Toyota points and condensor for Toyota distributor, parts from MAF	Done
7.	Installed new Toyota ignition wires, parts from Stevens Creek Toyota	Done
8.	Installed new Toyota PCV valve, part from Stevens Creek Toyota	Done
9.	New OME suspensions system: 4 OME springs, 4 OME shocks, 8 OME U-bolts, 4 OME extended shackles, 4 OME bushing kits, 4 Spector Off-Road u-bolt skid plates, 4 TPI greasable frame pins, 8 Toyota frame-pin screws. Most OME parts were purchased from 4Wheel-Part-Wholesaler, stock frame-pin screws bought from SOR.	Done!
10.	Replaced stock steering stabilizer with OME stabilizer. Notes: Task no. 10, 11, 12, 13, 14 and 15 were executed concurrently. Parts came from 4Wheel-Part-Wholesaler.	Done!
11.	Rebuilt steering arm center - with rebuild kit from MAN-A-FRE	Done!
12.	Rebuilt front end - task included replacing new knuckle bearings; inner/outer wheel bearings, seals and gaskets. The rebuild kits came from TPI (all bearing are Koyo bearings, new gaskets, felts, axle seals,..)	Done!
13.	Rebuilt steering system - Replaced all tie-rod ends and rods with Toyota tie-rod ends and rods parts bought from Scott Tate of Sterling Lexus.	Done!
14.	Replaced the original Warn Lock-O-Matic hub with brand new Warn Premium locking hubs bought from NorCal swap meet with all new hub bolts. This task was completed as the same time as task#12	Done!
15.	New rebuilt air pump	Done!
16.	Rebuilt brake system - including new Toyota brake booster, new Toyota master cylinder, new (4) Toyota drums, new (8) Toyota brake shoes, new Toyota flexible (2) hoses, new stainless steel MAF DOT approved front and rear flexible brake hoses, All new Toyota (8) brake wheel cylinders. Most other parts came from the local Stevens Creek Toyota. Brake booster and master cylinder both came from Scott Tate of Sterling Lexus. Notes: Toyota parts are more expensive but last much longer and safety comes first!	Done!
17.	Fix the exhaust leak, new Toyota manifold gasket/bolts/studs/nuts, have the manifold planned by machine shop if needed. All parts came from Stevens Creek Toyota . I have no exhaust leak after testing/checking. Parts saved!	Done!
18.	New exhaust system - 2.25" Aluminized pipes with Turbo Flow Master	Done!
19.	New Toyota carburator and Toyota fuel filter. Carb bought from SOR, fuel filter bought from Stevens Creek Toyota	Done
20.	5 Superior 15x8 White Spoke Superstar wheels with 33x12.5 BFGoodrich Mud Terrain's. Tires bought from Price Club, wheels bought from American Tires in San Jose.	Done!
21.	New Toyota brake and clutch pedal pads from SOR	Done!
22.	New front seat and rear jump seat upholsery, parts came from Spector Offroad, the style is identical to stock	Done!
23.	Replaced the current chipped and cracked steering wheel with a great condition steering wheel bought from a TLCA lister	Done!
24.	Replaced the the new Toyota gas cap, gas cap bought from Stevens Creek Toyota	Done
25.	New cooling system: new Toyota water pumps, new Toyota thermostat, new Toyota radiator. The hoses bought from Cool Cruiser of Texas. New Toyota belts. Toyota parts came from Stevens Creek Toyota and Scott Tates of Sterling McCall Toyota.	Done
26.	Touch up the paint where neeeded. Waxing and buffing	Not yet
27.	Original '63 Headlight bezel bought from a local lister. This bezel is quite rare that I thought I couldn't find one.	Done
28.	Repaint the fiberclass roof cap. New aftermarket roof cap weather stripping and head liner from CCoT.	Not Yet
29.	Repaint radiator shield and install new radiator Toyota emblem. Emblem bought from Scott Tates	Done
30.	Try to get the fog out of the windshield replace if needed. Bought new OEM tinted windshield at Stevens Creek Toyota. I decided to keep the original windshield and sold the new OEM one to Jim Miller	Done
31.	New 3-point seat belts from CCOT	Done!
32.	Used but perfect condition dash pad boght from Bruce Lutz (LCML lister)	Done!
33	New Toyota sun visors	Done!
34.	Safari roof rack - Heavy Duty roof rack bought from SOR	Done!
35.	Hella 4000 Offroad light kit and Hella 1000 Offroad light kit. Lights to be mounted on the roof rack. Lights bought from LCC, a total of 4 offroad lights and 2 separate light relays and wiring harnesses	Done!
36.	WARN 8274-50 Winch from Clemson 4 Wheel	Done!
37.	New OEM slave clutch cylinder and OEM flexible clutch hose - both bought from Stevens Creek Toyota. To be installed at the same time as task #52 (New clutch works).	Done!
39.	Hella H4 55/60 replacement headlamps. Light bought at Local 4wheel-parts-wholeseller	Done!
40.a	Traction aiding devices / Differential rebuilds - Install ARB Air Lockers front and rear, and rebuild the front and rear differentials at the same time! Differentials rebuilt kits contain carrier and pinion bearings/races, pinion nuts and pinion seals. ARB lockers came from TPI, rebuilt kits came from MAF - all bearing are Koyo's. Since the installation of lockers requires expensive tools for pretty much a single usage, I sourced out the installations to *Rear End Specialty* in Santa Clara, California and saved money by removed and installed the third members myself. Futhermore I also install the air compressor and do electrical wirings and air line routings. Note: when installing the air locker into the rear differential, I realized that new ring and pinion are needed (that explained the howling in the rear end) therefore I bought new Precision Gears ring and pinion from Reider Racing, I also bought the mini installation kit for this rear end from the same vendor. Since Precision Gears pinion has fine spline I had to replace the flange with a new Toyota fine spline flange bought from Scott Tate at Jay Marks Toyota. The complete rebuild and upgrade of the differentials with ARB air lockers has unexpectedly costed me soooo much.	Done! Both front and rear.
40.b	On Board air - Install the ARB air compressor	Done!
41.	Toyota mini-truck power steering, parts included: - JTO mini-truck PS gear box bracket. - JTO saginaw pump bracket, looks just like the BTB bracket.. - JT0 custom high pressure hose.. - Rebuilt '75 Chevy V8 truck saginaw pump. - '79-'84 used mini-truck gear box. - IFS mini-truck PS cooler and returned barb from junk yard. - Early 80's Volvo wide pulley for the sagnaw pump from junk yard, - Returned hose and stainless steel clampsfrom Napa. - Grade 8 nuts/bolts/washersfrom Orchard Supplies Hardware. - New longer belt at Kragen. - ATF Fluids.	Done
42.	Transmission gear reduction / H41 tranny - Replace stock 4speed transmission with non-USA Toyota Land Cruiser compound low 4 speed tranny (first gear ratio is 4.93) from SOR. Notes: the compound low tranny and 3 speed transfer case will be installed at the same time. New tranny gasket kit was bought from Stevens Creek Toyota.	Done!
43.	Transfer case gear reduction / J30 transfer case rebuild - Replace stock 4speed transfercase with late 3 speed transfer case (low gear ratio is 2.31), transfer case to be rebuilt before matching to non-USA tranny. Notes: I bought an used '73 transfercase from PMC swap meet and a new '74 (transition year) input gear from Scott Tates at Jay Marks Toyota to match this 3speed transfer case to the 4speed non-USA transmission, I also replaced the high speed gear and idle gear cluster with new gears from Spector Off-Road .Transfer case rebuild kit bought from MAF, the kit has all Koyo bearings, seals, gaskets, idle gear shaft pin, nuts, boots and other small parts. The special replacement Datsun B210 rear axle bearing was bought from Fremont Nissan (if you ever wonder, the bearing is made in Japan by NSK). I also bought 2 spacers for the input shaft from Warden's Automotives.	Done!
~~43.~~	~~Marlin Crawler gears/transfercase when available~~. *** Marlin no longer makes LC crawler gear
44.	New electricals - Dual Optima red top batteries with stock high output (80amps) alternator and battery isolator. 2 Optima redtop batteries came from Oakland 4Wheel Parts Wholesaller during yearly sale every March. Stock High Output alternator came from MAF. Voltage regulator came from Sterling Toyota. Warn isolator bought from 4Wheel-parts-wholeseller. New longer 1-guage battery cables. (4) new Military spec'ed battery terminals.	Done!
45.	Toyota Torque Reduction starter from Stevens Creek Toyota	Done!
46.	Man-a-fre rear fender flares, it's going to be very tough to cut those perfect rear fenders :-(	Parts acquired
47.	New trail communication gears - Cobra 18UWB CB and Firestik II Antenna Kit. CB bought directly from Cobra, antenna kit (which includes 4' Firestik antenna, mount, 18' wire, stainless spring, connector, CB hanger) bought from Fry's Electornics	Done!
48.	New stereo system - Bazooka 8" subwoofer came from The Good Guys. Sony CD player with 40wattsX4 output. CD player bought from Fry's Electronics. Bose 101 Environmental speakers bought from Fry's Electronics.	Done!
49	Semi-floating axle - Rear end rebuild - Replaced rear inner axle seals and rear wheel bearingss. Task was done at the same time as Task 40. Seals and gaskets were Toyota ones. Toyota seals bought from Sterling McCall Toyota, bearings bought from Stevens Creek Toyota (this axle housing and axle shafts were later sold to Morgan Fletcher because of later full floating axle swap)	Done!
50.	Rebuild ignition system - Pertronix Ignitor (partno. 1665) and Frame Thrower Epoxy 40,000 volt coil came from Northern Auto Parts, MSD 6-Offroading Ignition control which was bought from Summit Racings.	Done!
51.	Hi-Lift 48" Casting Jack and Hi-Lift tower mount (4" high). The jack bought from a local new 4x4 shop in Fremont.	Done!
52.	New clutch works - to be done at the same time as task#41 and #42. This includes new clutch, pressure plate, throw out bearing, pilot bearing and rear main seal. All new (no remanufactured) parts bought from Stevens Creek Toyota.	Done!
53.	New bumper - MAF 4+ Plus Bull Bar with Warn 8274 mount including stainless mounting nuts/washers/bolts	Done!
54.	New Confer rear lense protectors bought from Bruce Lutz	Done!
55.	Confer gas can holder bought from Bruce Lutz	Done
56.	New custom Butch Built dual optima battery tray be installed the same time as task#44	Done!
57.	New "Toyota Land Cruiser" side hood emblems	Done!
58.	New front hood to bib bumpers and hood to side fender bumpers	Done!
59.	Replaced the 2 screws in front of gauge cluster with new stock screws	Done
60.	Revovery gears - 30' recovery strap and ARB snatch block bought from LCC	Done
61.	ARB air hose kit - bought from LCC	Done
62.	5-gallon Bliz gas can bought from 4wheel-parts-wholesaller	Done
63.	Confer gas can holder mount bought from 4wheel-parts-wholesaller	Done
64.	New clutch hydraulic - New OEM clutch master cylinder and new OEM clutch slave cylinder and new OEM flexible clutch hose. Clutch slave and hose bought from Stevens Creek Toyota, Clutch master bought from JTOutffiters	Done!
65.	New Energy Suspension polyurethane body mount kit, kit bought from JTOutfitters	kit acquired
66.	Rear full-floating axle swap - Rear end rebuild - I acquired a non-usa/Autralian FJ40/45 full floating axle and swapped the stock semi-floating axle for this FF axle. The axle was rebuilt with new Timken bearings and Toyota seals and gaskets before being swapped in.	Done!
67.	Installed the extended OEM axle breathers and new rubber lines	Done!
68.	Installed new OEM mechanical fuel pump. Pump from Ebay	Done!
69.	Installed Northen Tools rear pintle hook	Done
70.	Installed new OEM oil pan gasket. Gasket from Ebay	Done!
71.	Installed new OEM valve cover gasket. Gasket from Stevens Creek Toyota	Done!
72.	Adjusted the valves according to specs	Done!
73.	Original tailgate from soft top fj40. Dave Tay found this tailgate for me. It came a guy in L.A. I looked for this tailgate for the past 3 years. To complete everything I bought 2 hooks and one latch from Stevens Creek Toyota	Tailgate bought!
76.	Polished the 2F valve cover and dressed it up with the OEM "2F" sticker from SOR	Done!
77.	Strip and repaint the air filter unit also dress it up with OEM air filter sticker from SOR	Done!
78.	Auxillary Gas tank - Parts included: - Confer Aux gas tank with skid plate kit bought from TPI (thanks to Joe Turpin of JTOuffiters who pointed out that TPI has the very last (discountinued) gas tank and the kit was deeply discounted. - Early OEM gas sender and gasket bought from Stevens Creek Toyota. - OEM gas cap bought from Stevens Creek Toyota - 6-port selector valve bought from JCWhitney.com - Roderick T. Daebelliehn sold me a complete OEM filler neck/gas door/backing plate cut out of a rusted out '74 FJ40	Done!
79.	Rocker Sliders - Luke Porter at 4x4 Labs custom made a set of rocker slidesr that hide underneath the stock rockers and running boards, the sliders saved my rockers/running boards at Rubicon.	Done!
80.	High Clearance Rear bumper - Luke Porter custom made this baby.	Done!
81.	Interiror Liner X - have the interial proffessional liner	Not Yet
82.	Undercoat the tube with ruberized paint	Not Yet
83.	Repaint the truck professionally	Not Yet
84.	Mini-truck diskbrake conversion: - New Timken wheel bearings and new seal/gasket kits. - New Aisin locking hubs (OEM) - New Downey flexible brake lines to the calipers - Rebuilt calipers from Autozone - New disk rotors - Longfield birfields	In Progress
85.	Rubicon damage repair - my truck was damaged after the expensive Rubithon 2001 trip, here is a list of repair: New front driver side OME spring: I bent this spring. Ouch! Thanks Alan Wesley New rear passenger side OME spring: I bent this one too. Ouch! Ouch! Thanks again Alan All new anti-inversion OME shackles to help prevent the above bent springs in the futrue 2 new BFG MT tires: thanked to Cosco Harzard Replacement - got two new free tires New Conferr Bull Dog clamps to replace the Wilderness HD clamps which were not strong enough New Toyota OEM driver side fender Cut couple feet of the winch cable and had new loop made by proffessional shop New front drive shaft to replaced the twisted one - Thanks Jimmy Miller	Done!