Pound Puppy rescue rebuild

this is a ridiculous transformation...in a great way!

 

Headliner install today. Was all anxious about it. It went much easier than I thought it would.
First, don’t install the rear lower side panels before all this. Makes it harder to install the upper seatbelt panel. Get everything in order. I made sure the wire harness along the front of the headliner was in
place. So the console could just plug in. So what I did then was tuck the headliner in on one side under the door seal.
I used headrests up as high as possible to support it as I positioned it. Then went around to the other side and tucked it up under the door seal on the other side. This was pretty cool, as the rear has a detent in the corner so it positioned really well. I forgot to take pics until I’d already screwed in the console. So get the sides in first, then the console and no more worries about it falling or being out of position.


Sorry crap photo, the sun was too bright today! Early February in Vancouver Island, I’ll take it!!!

 

Ok, someone actually posted a whole thread on what this piece was. It’s just above the drivers head on the headliner and it’s just over 1” square. Seems to do nothing. No it’s not a GPS antenna. No it’s not a tracking device from Google - though gods knows they probably thought of it.

It’s just there to hold the headliner in place to offset the grab handle from the other side. To remove, pop the cap off with a small flat screwdriver. There are slots. Then take a flat plier, like my duckbills and grab the tin clip and pull it out. Then the headliner falls out. Installation is easier. Put the tin clip
back into the base, make sure you get it in the right way. Then put the cap back on and when the headliner is in position just pop it into the slot until it clicks. Easy.

 

Four pics of installing the A pillar covers. Again, they just clip in the bottom, tuck in the airbag skirts, and then tuck it under the rubber door seal. Toyota did a magnificent job with this door seal
and how it is designed to help structure. It makes removal and working on components easy as anything I’ve ever encountered. Thank you, Mr Toyoda.

 

Here it is, essentially done. Waiting on Amazon for door stopper for drivers door. Thanks to everyone for helping me out. I’ve received some great information on this forum and everyone seems really great and very helpful.

 

iPad really does take crappy photos.

 

Well done OP. Looks fantastic!

 

Real nice ! Something to be proud of....Certainly have more ambition than I. Hell I cant even wash mine....

 

That looks awesome. Hopefully I'll see you cruising around the island at some point.

 

Well, yeah! Look for green 60 series land cruiser with snorkel and all the extras, as well. This will hopefully be my daily for working around. Driving lights on order.

 

Hey, I’m big offroader as well. Someone recommended these, and I liked them so much
I ordered a set. They arrived right at halftime of SB. Along with my door stopper!!
These Colby Valves are really high quality! If anyone is looking for what I’d say is the best
tire valve replacement for emergency use, then these are them. www.colbyvalve.com

 

What an amazing transformation!!! I really have enjoyed following this build / restoration. Thanks for sharing and congratulations!

 

I just realized, one month from first post to almost last. Longest month of my life? Not sure, but
it's been amazing what has all happened through this. Sheesh..

 

Next step. Timing Belt. My buddy sent me a video of a step by step. I’ve not had good luck
with these in the past. But this one looks much better and doable, must be Toyota quality
https://www.youtube.com/watch?v=I9nyGH_mKGA

So I’ve got a kit and will get to it. Pics to follow as I go along.

 

I found out one of the TPMS sensors, specifically the RF had corroded and would not allow air in or out. So I tried to pull the core and it was completely corroded. After checking the govt vehicle inspection requirements for BC I determined this is not a legal safety device and not a requirement for the vehicle. In light of cost, I didn’t feel like buying one sensor for a system that seems to have inherent issues.
I removed all four today. Installed rubber valve stems. TPMS sensors went into the glove box.
The tire store manager wasn’t able to remove the core either.
Can someone direct me to that link which discusses splicing the two wires to fool the system and extinguish the flat tire light? I think there is a connection just behind the glove box?

 

Found it. In Tires and Wheels forum
“Disable TPMS”.

 

UPDATE: Removed TPMS sensors and had tires rebalanced with rubber valve stems.
Increased Tire pressure to 40 psi. Loaded up the CanAm 80 with snow plow and drove it for
150 miles. Mileage average 18 mpg.

 

Today in an alley with snow/hail storms we swapped out the timing belt. Coldest day
of the year it seemed! But it’s done. Original timing belt had started to separate, some
belt teeth showing metal strands. PHEW , got it done in the nick of time! So
217,450 kilometres driven on original timing belt. Don’t recommend that!
Water pump was leaking quite badly from completely blown gasket. Everything else was
good. The fan pulley bracket bearing seems a bit weak. I didn’t order one as it was about
$200 up here and I was just trying to ration money. So I’ll keep an eye on it until summer.
I still have to replace plugs, air and fuel filter, PCV. I’ll probably take a close look at it then
replace.
We hooked up the OBD reader, cleared the codes. Went through the whole engine. O2 sensors
indicated normal. Everything else seemed to be normal in working order. So I took one pic
of the engine on teardown and that’s it. Been a long day.

 

The is awesome. Have to say though being a previous ironworker and welder, this truck isn't in that bad of shape LOL some of the work trucks I used after two or three years looked way worse than this haha. The roof being banged out like that makes sense to me as we sometimes would use the truck as a makeshift scaffold sometimes to weld stuff. The headliner in your truck doesn't make a whole lot of sense only because it's an reg cab , in our work trucks they were ext cab and piling guys in and out after working black iron stuff would get everywhere. Tossing dirty toolbags , safety harnesses etc around would make it happen too. My 2005 f250 looked way worse with only 160k. Our company looked at them as tools that were used hard.....

 

Take care of your equipment. Period. Whether it’s your work truck or your micrometer.
I was a land surveyor in the north for a long time. We abused trucks terribly, but never
to this point. Enough said on that topic.

 

Mechanically they were in perfect order the company made sure of that. Maintenance was religious. Cosmetics on the other hand , nope.

 

Here are some pictures. A request was made to post them, as apparently some think they can go for long time without
tending to timing belt replacement. I count myself really, really lucky. This was original belt, 217,450 kilometers on it.
135,000 miles. When I pinched the belt between my fingers I could feel 'bubbling' separation internally. There are exposed
wire strands on two of the cogs. The water pump was ruptured in two locations. Lots of crystallization underneath inside. Oh, and it had a plastic impeller on the water pump. Is that an indication of original water pump as well? That is what I was told.
Tensioner was still quite good, no leaks. Here are pics.

 

I have seen a lot worse on belts with less mileage, not so bad, but still a concern.

 

Baseline tune-up list: 217,750 kms on 4.7 litre with no maintenance history:
As it states I’ve been driving pound puppy for a while, getting an average 18 mpg. I’ve hit
speeds of 160K or 100 mph a few times just to have fun. It’s smooth, no noises knocks or
pings. Overall, really solid and handles really well. What I’ve got so far on my list and from what
others have suggested I’m just assembling parts.
Air filter , cabin filter , NGK iridium plugs , PCV valve.
Someone mentioned Mass Flow but not sure
what they meant? Throttle body inlet is a bit grimy but not sure if I should spray anything in there
like carb clean unless it’s running or whether that’s even the way to clean it.
I’ve run OBD sensor checks and Bank2#2 O2 sensor arrives in a day or two so I’ll swap that out.
Surprisingly enough there are no more engine codes and it runs well.
Transmission: I have a friend who has offered to talk me through a proper trans flush, it apparently can take some time but to do it right it will. So temps on the transmission are in the bottom third of the gauge so the flush is all I feel it needs. This truck never towed or hauled loads in the past.
Rear axle is tight, u-joints are good. I’m not going to bother with diff fluids for now, maybe before next winter but it’s sealed and not being 4WD has never been underwater or mud.
Exhaust is solid, I will cut tail end off and extend to edge of box. Getting exhaust out from under the truck eliminates the corrosive damage of exhaust gasses.
Brakes: serviced at intervals at a cheap service chain - New highest quality rotors, pads and calipers
are on the list for end of summer so I go into winter with new brakes.
Radiator: coolant was completely replaced last week with timing belt. Internals of rad were in fantastic shape with no damage to any fins. It’s done.
AC will be flushed when I replace the entire heater box with better newer unit in summer. This truck won’t fit in the shop, too wide so any open door work has to be done outside in nice weather.
Anything else?

 

How much $$ do you estimate you have in this puppy so far?

 

More than I wanted to, but two weeks sick cost me an extra week + in body shop. Less than it’s worth.
If I’m really happy over the summer then I’ll go ahead with the SOS lowering and air bag kit.
I have to rebuild / re-gear transfer case in my Land Cruiser, parts alone are $1K. It’s the priority now,

 

Really enjoyed reading about your journey.Thanks for sharing.Looks good!

 

Awesome.... vision + enthusiasm + skill = SUCCESS

 

Thanks for the compliments. Makes it easier to pick away at niggling little things.

 

THANK YOU . @audiowize
You sir, are a gentleman among gentlemen! The bumper arrived and I flashed down to Victoria to pick it up. It has completed the pound puppy! Now it looks like a truck. I was bushwhacking yesterday up on the mountains or I’d have washed it first. But it’s on and looks perfect.

I have a question - can anyone let me know what I can use to plug the sensor holes in the bumper? Is there a Toyota part number or does anyone have a plug or grommet they can recommend? I’d sure appreciate some help on that.