Backstory

Joe Tatar’s 1977 FJ55, known as Wart Hawg, came in as a combination repair and upgrade project. The truck is a mix of modifications gathered over the years — aftermarket EFI, custom steering, oversized suspension and tires, and various one-off solutions. Each system had been touched in different ways, which meant every repair required additional inspection and adaptation to work around the existing setup.

The Challenge

The rear ARB Air Locker was not functioning. When the differential was opened to inspect and reseal, it was discovered that the carrier assembly was seized in the axle. The retaining bolts on the ring gear had been over-torqued in a previous repair, leaving the differential permanently stuck.

The only way forward was to remove the carrier destructively and replace the ring gear. A new ring gear was installed, and the gear mesh and backlash were set up properly during reassembly.

Key Repairs & Upgrades

• Rear Differential & Air Locker

  • Removed seized carrier

  • Installed new ARB Air Locker and seal kit

  • Replaced ring gear and completed gear mesh setup/backlash adjustment in-house

  • Rebuilt rear axle with new bearings and seals

• Steering

  • Fully disassembled, inspected, cleaned, resealed, and reassembled a late 60-series steering box

• Ignition

  • Diagnosed ignition system issues

  • Replaced and upgraded ignition modules for reliable spark

• Cooling System

  • Installed new radiator, modified fan shroud, replaced hoses, and serviced coolant

• Power Steering

  • Upgraded to a Saginaw pump with new fittings and fluid service

• Brakes

  • Installed new OEM front calipers and hardware

  • Replaced rear bleeder valves and bled system

• Electrical

  • Fabricated and installed a higher-capacity fusible link

Summary

Wart Hawg was a complex, non-standard build with layers of previous modifications. The project required destructive removal of a seized differential, complete gear setup, a full steering box rebuild, and solutions across ignition, cooling, braking, and electrical systems.

This project is included to show the range of repair and diagnostic capability at CEV. While the future focus is on complete mechanical overhauls and standardized builds, Wart Hawg represents the type of complex, mixed-modification rig we’ve successfully brought back into service.