Axle build with ram assist (1 Viewer)

[PPFJ60]

I have been planning on building a front axle to swap mine out with and the time has come to get it done since mine is now bent.

I have a stock FJ60 axle that I am going to start tearing down tonight. Here is a list of what I have.

1) 30 spline Longfields.
2) Longfield hub gears.
3) Front Range Off-road hub studs.
4) Knuckle rebuild kit from Marlin.
5) Axle gusset kit from Marlin.
6) Spring perchs from Ruff Stuff.

I will do the C&T since I am already sprung over. I am planning on doing a ram assist at the same time but havn't order parts for that yet. The work is straight forward enough but I would like inputs on what to watch out for while doing the build, helpful hints and suggestions on additional items I may be over looking.

 

[LC_Hamma]

Get a hysteer arm that allows you to mount the ram off the rear of the pass. knuckle. Are you running tie rods or rod ends? Get a knuckle stud upgrade kit too.

 

[EWheeler]

For the trussing, how do you plan to keep the housing from warping?
Weld and in/let cool & repeat a billion times, build some type of jig, ????

I have a suspected bent front 60 housing and have a spare laying in the trailer. When I swap them out, I want to truss it along with knuckle ball gussets to add some beef, but am a little worried about warping the housing.

 

[handcannon]

For the trussing, how do you plan to keep the housing from warping?
Weld and in/let cool & repeat a billion times, build some type of jig, ????

I have a suspected bent front 60 housing and have a spare laying in the trailer. When I swap them out, I want to truss it along with knuckle ball gussets to add some beef, but am a little worried about warping the housing.

X2 I have the same concern for a 60 axle I am working on. I would like to hear some input from others who have done this already.

Don

 

[PPFJ60]

I already have the 4X4 labs high steer that puts the tie rod behind the axle. The rod ends are GM 1 tons ends.

I am planning on doing the stitch welding with cooling time in between to get the gussets installed. This is hard for me since I tend to push forward when working on something.

I was thinking of putting the 5th stud on the steering arms.

I tend to pay tuition to the school of Hard Knocks Learning so any idea's or tips would be appriciated.

 

[PPFJ60]

Pictures of last nights progress.

 

[Isotel]

lookin good Chuck!

Marlin HD Inner Seals, Cromo knuckle studs, and those new HDPE seals that take the place of the rubber/felt's would be the way to go. i dont know who make those, but we put a set on randy's pickup out at the shop and they look cool!

Pretty Penny is getting some BLING

 

[EWheeler]

....those new HDPE seals that take the place of the rubber/felt's would be the way to go. i dont know who make those....

Longfield.

http://www.longfieldsuperaxles.com/products/TOYOTA-KNUCKLE-LIFETIME-WIPER-SEALS.html

 

[PPFJ60]

Yesterdays grinder progress. Even with a plasma cutter it still takes lots and lots of grinding.

 

[PPFJ60]

Still need to weld the drain plug shut.



I tried to order the seals from Longfield but the ordering process does not seem to be working correctly. I will have to give them a call tomorrow.


I was told that the diff armor from Marlin can be fit to the FJ60. Has anyone done this?

 

[PPFJ60]

The cut and turn is done and the drain hole filled in.

Sounds like my parts are being delayed by a week. I don't expect to have the knuckle rebuild parts and the axle ball gussets in until the first week in February.

I still need to remove the bent axle and tear it down so that will take a good part of this week since I only get short amounts of time between work and helping kids with home work.

 

[GLTHFJ60]

Why did you weld the drain plug shut?

 

[PPFJ60]

I welded the drail plug shut because I keep grinding off whatever I weld on to protect the drain plug. I have the low profile plug that is currently getting ground off. I will use a bolt in the bottom stud of the diff to use as a drain and I can always suck the lube out the fill hole.

 

[fj40forlife]

Here is a 60 axle I just build

Fab up Diff cover. truss. shock mounts and knuckle ball guesset.
Cut and turn and ARP studs

 

[PPFJ60]

FJ40FORLIFE,

Looks good!

Looks like your truss is a tube with a gusset plate is that correct?

If so it seems like a good way to go.

I added the same kind of diff protection to the rear axle diff cover but I am thinking I need something a little stronger for the front. I made a football helmet style protector of the front of the old axle and it is pretty bent up and ground off and that was only on for one year.

 

[fj40forlife]

Thanks, yes its a 1 1/2 tubing with a gusset for the truss. Diff cover is made out of 1/4 steel. really strong has taken rocks pretty good

 

[PPFJ60]

I was drinking a couple of beers thinking of what to do about diff protection. I wasn't coming up with anything. I had a friend show up and after a couple of more beers he suggested cutting the center of the bent axle and using it as a diff protector.

I welded a 1/2" steel rod to the diff, cut a 1 3/4" hole around the fill plug so I could weld a 1 3/4" piece of tube around it. I like the way it turned out.

 

[PPFJ60]

Oh yeah I am still waiting for parts to start putting things back together again.

 

[PPFJ60]

Finally the spring perches came in so I made some progress.

The perches and gussets are installed. The axle is currently installed and painted. I still need to fab up the anti-wrap bar mounts. When that's done I can install the truss.

 

[GLTHFJ60]

Looking good!

Front anti-wrap bar?