4x4Wire's TrailTalk Forums: FJ60 2F thermostat replacement

Well, as with most older rigs, sometimes you fix stuff, and in turn, find other problems. This is my friend's 1985 Cruiser, with a 2F. A few weeks ago, we swapped out a water pump, only to find the gasket between the thermostat housing and the front of the head had failed. We verified this with a pressure check.

Here we go:

Tools Needed

5/16" socket or common tip screwdriver for hose clamps
Universal socket adapter, 12mm and 14 mm hex sockets/rachet
Torque wrench, 1/4" dr. (value 156 in-lbs or 13 ft-lb)
1/4" to 3/8" drive adapter for torque wrench if you lack 1/4" drive sockets
6" extension
Wire brush for cleaning
Catch basin for antifreeze for kid and critter safety

Consumeables

Hi temp RTV for holding gaskets in place, no sealant boogers
Emery cloth for cleaning mating surfaces, and/or razor scraper
Approx 1 gallon of premixed coolant

Teardown

If you feel you really need the fan shroud out of the way, you'll want to remove the battery to get at the bolts on the passenger side, as the AC condenser unit is also mounted there. Otherwise, the fan shroud can remain in place.

Remove the top 4 bolts of the thermostat housing and lift out of the way. Next, remove the pax side hose and move it out of the way.

You will see the t'stat and its top gasket here:

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Note there are 4 vacuum lines on the driver's side of the lower thermostat housing. They will need to be disconnected if you need to remove the lower thermostat housing. In this case, it was necessary, as we needed to replace the housing-to-head gasket.

If you are only needing to replace the t'stat along with the middle and top gaskets, this step isn't necessary.

Old t'stat and gasket on the left, new on the right:

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If removing the lower thermostat housing, do the following:
Remove the 4 vacuum hoses for the coolant sensors on the right, then with the socket and universal, remove 2-14mm bolts, then remove the housing to clean up.

Coolant orifice in head:

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Yummy, clean up and install new t'stat housing gaskets here (aft of lower unit)
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and here, where it's sandwiched between the lower and upper housing; make sure you swab any fluids out of the lower t'stat housing where your bolts thread back in:

Reassembly

TIP: I use the bolts to align the gaskets while the RTV sets up, so I'm not fighting this during reassembly. Let it set up enough so that the gaskets don't slide out of position when you reassemble it. This is a good time for a little break.

When you put it back together, the two bolts on either side as you see above gets torqued to 156 in-lbs (13ft-lbs).

Reinstall your vacuum lines and hose, drop in your thermostat and gasket, then install the upper thermostat housing; the 4 bolts here do not have a torque value; just snug 'em up.

Top off and burp the baby; yer done!

Parts List

2F t’stat Toyota 90916-03052 $34.82

2F gasket Toyota 90430-43002 $2.86 This didn’t come in with the t’stat. It’s the one that sits on top of it.

Fm NAPA w/ AAA discount:

Gasket 35307 $1.65 this is the one between the top and bottom halves of the t’stat housing

Gasket 5021 $1.35 housing to head #1 better fit than #2
Gasket 35494 $1.65 housing to head #2 thicker than #1, but also more brittle. We're just keeping it around for a spare.

Edited by kewlynx (03/27/09 03:58 AM)





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