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Jacket
06-20-2011, 08:41 PM
The choke cable on my 40 broke the other day; coincidentally the next time after my wife drove it to the store.....

In doing some parts research, it appears that Toyota made a choke cable for 1/75 to 7/76 FJ40's under one part number, and then another cable for 8/76 to 1980. The 1/75-7/76 is unavailable, but Toyota still has a number of cables left for the 8/76 to 1980 - but no obvious difference in the two parts with the diagrams and info in the catalog. Mine is a 5/76.

The date boundaries coincide with the minor changes in the 2F carb, which makes me think there may be a difference in how the two different cables attach to the carb. In the picture of mine below (taken of the back of the carb looking down from near the brake booster), you can see the choke cable marked with the small red dots, and it attaches to the carb in two places marked by the arrows.

http://www.risingsun4x4club.org/uploads/Jacket/FJ40/carb2.JPG

Can anyone with a 8/76 to 1980 rig show me their choke attachments on the back of the carb to see if they are similar/same? Subzali?

subzali
06-20-2011, 09:19 PM
Mine is a 10/76 and it looks pretty much the same as that. I can't tell any differences. I can snap a pic in the morning and post it tomorrow night if you like.

Jacket
06-20-2011, 09:33 PM
Hmmm-then why have a different part number? There's gotta be something different.

Rezarf
06-20-2011, 10:30 PM
Sorry Matt I'm a 12/75 vehicle.

subzali
06-21-2011, 06:05 AM
Maybe different length for some reason? :dunno:

Here's mine:

RicardoJM
06-21-2011, 06:10 AM
...but no obvious difference in the two parts with the diagrams and info in the catalog.

It would seem to me that the difference would be length and/or knob; most likely something different with knob is what I would guess.

mukker4life
06-21-2011, 06:53 AM
http://farm3.static.flickr.com/2604/5856095475_af0859cb66_b.jpg
http://farm6.static.flickr.com/5316/5856095063_5c4426e1c1_b.jpg

I'm new at this but mine seems to be missing a piece. The smiley face piece does not have the rod piece in it?

subzali
06-21-2011, 07:49 AM
Mine's a braided cable, looks like you guys might have a solid wire?

Jacket
06-21-2011, 09:11 AM
Thanks for the pictures. So much for my carb theory.....

It would seem to me that the difference would be length and/or knob; most likely something different with knob is what I would guess.

Possibly. I thought all the late model 40 knobs just said "Choke" and the pictures look the same.

subzali
06-21-2011, 09:43 AM
mine says "CHOKE":
http://risingsun4x4club.org/forum2/attachment.php?attachmentid=14438&stc=1&d=1251655086

Jacket
06-21-2011, 10:10 AM
I'm new at this but mine seems to be missing a piece. The smiley face piece does not have the rod piece in it?

That assembly is what opens/closes the choke valve. Is your choke working?

Jacket
06-21-2011, 10:16 AM
mine says "CHOKE":
http://risingsun4x4club.org/forum2/attachment.php?attachmentid=14438&stc=1&d=1251655086

Looks just like mine, albeit my dash is much cleaner. :bolt:

Edit: You need a gamiviti 40 series mic holder. :)

Rzeppa
06-21-2011, 11:01 AM
Mine's a braided cable, looks like you guys might have a solid wire?

All 4 of my cruisers have solid wire. I think that's because the spring return on the choke isn't that strong so the solid wire can push the choke open?

subzali
06-21-2011, 01:09 PM
Looks just like mine, albeit my dash is much cleaner. :bolt:

Edit: You need a gamiviti 40 series mic holder. :)

meh. Washing the interior of an FJ40 is overrated.

Thanks Matt, got it covered (http://risingsun4x4club.org/forum2/showpost.php?p=117330&postcount=14) ;)

All 4 of my cruisers have solid wire. I think that's because the spring return on the choke isn't that strong so the solid wire can push the choke open?

I have to push/pull my choke to open/close. Didn't even realize that the choke has a spring return. I'll have to look at mine a little closer.

Sorry to hijack your thread Matt! :boozer:

Air Randy
06-21-2011, 01:10 PM
The older cables have the choke icon and have plain spring wound sheaths. The newer ones say "choke" and have a rubber coating on the sheath to help keep moisture out. Other than that, there shouldn't be any difference in length as the cable routing appears to basically be the same.

subzali
06-21-2011, 01:27 PM
maybe it's sheathed vs. non-sheathed like Randy said.

mukker4life
06-21-2011, 02:51 PM
That assembly is what opens/closes the choke valve in. Is your choke working?

My choke has seemed to work fine, I poked around a little and found that arm hanging down. Has a tiny clip that I think slid through the slot. Reattached it with the tiny washer on the correct side so we'll see if anything changes. :dunno:

Jacket
06-21-2011, 04:35 PM
The older cables have the choke icon and have plain spring wound sheaths. The newer ones say "choke" and have a rubber coating on the sheath to help keep moisture out. Other than that, there shouldn't be any difference in length as the cable routing appears to basically be the same.

Right - but the "newer" ones have two different part numbers across the date boundaries I mentioned - which would indicate something is different.

I left Jerry a message to go ahead and order the 8/76 - 6/80 part, so I'll soon know for sure.

Rezarf
06-21-2011, 05:41 PM
Took the words out of my mouth. Jerry will know, if not, he will work with you to get it right.

Jacket
06-26-2011, 07:56 AM
Jerry from Boulder Toyota ordered me the later model part and it arrived Friday.

http://www.risingsun4x4club.org/uploads/Jacket/FJ40/choke_cable/001.JPG

Knob and cable length look the same, but the new part is wrapped in a black vinyl sheath rather than the wound spiral wire (although it is conceivable that the same wound wire exists under the black sheath). And more noteably the clamping ends are different; the new part has a crimped metal cap.

http://www.risingsun4x4club.org/uploads/Jacket/FJ40/choke_cable/002.JPG

http://www.risingsun4x4club.org/uploads/Jacket/FJ40/choke_cable/004.JPG

I marked the places where my cable was attached to the carb and removed it. It had broken near the top just behind the pull.

http://www.risingsun4x4club.org/uploads/Jacket/FJ40/choke_cable/003.JPG

To put the new cable in, I lowered the steering column and removed the instrument cluster (after disconnecting the battery...). There's a 17mm nut behind the choke pull that you can see looking up from the floorboard, but getting a hand/wrench up there is nearly impossible. By pulling the gauge cluster and removing the speedo cable and wire plug, I was easily able to access the nut with a box wrench.

http://www.risingsun4x4club.org/uploads/Jacket/FJ40/choke_cable/006.JPG

http://www.risingsun4x4club.org/uploads/Jacket/FJ40/choke_cable/005.JPG

Threading the new wire through the fire wall was reasonably easily, although it takes some yoga and small hands to align the rod with the rubber grommet at the firewall. Once through I fed the wire into the two places on the carb where the choke cable is secured, and then found the 1 and only issue. The crimped end of the new part is slightly smaller in diameter than the old part, so the process of clamping the cable wasn't working.

http://www.risingsun4x4club.org/uploads/Jacket/FJ40/choke_cable/008.JPG

That clamp is basically a 5mm screw threaded into a clamping nut with a U-shaped end to hold the cable. The U-shaped section of the nut was too round/large to hold the cable securely.

http://www.risingsun4x4club.org/uploads/Jacket/FJ40/choke_cable/009.JPG

So I pulled this piece off (I had to cut out the screw because the threads were rusted and damaged), and put it in the vice to flatten it a bit to provide better clamping force. With the U-shape section flattened to more of a row boat shape, I put it back on the carb with a new 5mm screw and I was able to get a nice strong clamp. With that bit working, I screwed the cable rod to the choke mechanism and secured the knob to the dash and put it all back together. My old choke pull was pretty tight and resistive, but this new one pulls and pushes like butta.

And new bling for my dash. I guess I need to repaint the other knobs to match....

http://www.risingsun4x4club.org/uploads/Jacket/FJ40/choke_cable/011.JPG

So the short version of the story is that part no. 78310-90310 will work with the earlier 1/75 - 7/76 Cruisers with very little modification needed. According to Jerry, there were like 15 of these OEM choke cables for the 8/76 - 6/80 years still available from Toyota.

Rzeppa
06-28-2011, 12:00 PM
Very nice writeup Matt! And I like your resourcefulness in modifying the clamp to fir the new cable.

FWIW, there is spiral wound steel sheath under the black plastic sheath.