60 Series Axle swap with the Trail Tailor Coil Conversion

[4runner2FJ60]

Made some progress today so I'm finally getting around to posting on this thread. Sometime near the end of June @vbvagearhead hooked me up with the donor front axle. Picking and loading was a breeze when you have a forklift on hand. The summer got hot, but last weekend I started the blasting cabinets work and today got the small parts primed and painted. Axle is next, trying to keep inside the 70°+ degree weather for 2 part. Glad to be underway.

 

[dbbowen]

Heck yeah man! I think a huge mistake I made on my swap was not having a forklift haha

 

[4runner2FJ60]

Still had to unload it at home! But believe it or not, I had a trick for that. If you can get one of the Husky brand work bench desk things at Home Depot (no affiliation). They have saved me multiple times. Wheels, no wheels, two drawers, and..... ADJUSTABLE HEIGHT! Maxed out it was just shy of flush with the Decked drawer system in the Tundra. Not too bad making the transfer, then just rolled it in.

 

[vbvagearhead]

It’s coming together nicely Hunter!! I can’t wait to see all completed!

 

[4runner2FJ60]

Looking at brakes..... Looks like I should go with 95 and up rotor & caliper but my axle is 91. Any issues with this? 95 rotors look thicker for sure.

 

[dbbowen]

The coil swap did super well on the rocks in the PNW. The coils flex soooo much more than the leafs did and it’s so much smoother on the fire roads.

Need to extend the bump stops some to help with the rubbing, and desperately need a skid plate for the tcase. Oh and also figure out a way to protect the rear quarter panels

 

[TRAIL TAILOR]

The coil swap did super well on the rocks in the PNW. The coils flex soooo much more than the leafs did and it’s so much smoother on the fire roads.

Need to extend the bump stops some to help with the rubbing, and desperately need a skid plate for the tcase. Oh and also figure out a way to protect the rear quarter panels

Trail Tailor quarter sliders...

Jason

 

[dbbowen]

Trail Tailor quarter sliders...

Jason

With the prices on full bumpers these days that might be the move. Forgot you made those!

 

[TRAIL TAILOR]

With the prices on full bumpers these days that might be the move. Forgot you made those!

Built as ordered. Not on the website.

 

[boots4]

I just realized this was you on the trail. Glad to see you representing FJ60's out with that group. Your rig is super clean and it's great to see you enjoying it.

 

[dbbowen]

I just realized this was you on the trail. Glad to see you representing FJ60's out with that group. Your rig is super clean and it's great to see you enjoying it.

Oh man that was your monster 60 out there? That thing was Awesome. Idk if you noticed but i was like up under your cargo area trying to check out the quarter panel cut you did as you drove by haha There are like no 60s around here it seems like

 

[boots4]

Looks like pg 22 in my build thread has some pics of when I cut the rear quarters if you are interested.

Builds - Family haulin' - https://forum.ih8mud.com/threads/family-haulin.160807/post-3208942

 

[dbbowen]

Looks like pg 22 in my build thread has some pics of when I cut the rear quarters if you are interested.

Builds - Family haulin' - https://forum.ih8mud.com/threads/family-haulin.160807/post-3208942

oh perfect, thank you!

 

[4runner2FJ60]

Third and hopefully final axle blasting commencement this morning. Cleaning up pretty fast. Very tempted to buy a new OEM diff housing, worst part of the blasting. Last weekend was new hardware install w little time to work on conversion. Found I had some worn outer splines to.

EDIT: the brackets on the axle are the worst part of cleaning it up. Carrier was no problem.

 

[dbbowen]

Third and hopefully final axle blasting commencement this morning. Cleaning up pretty fast. Very tempted to buy a new OEM diff housing, worst part of the blasting. Last weekend was new hardware install w little time to work on conversion. Found I had some worn outer splines to.

EDIT: the brackets on the axle are the worst part of cleaning it up. Carrier was no problem.

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@Dubs2017 can tell ya. I’m dealing with worn 80 splines over here working on this 80 in my garage. Looked JUST like those.

Man I wish I sand blasted my stuff. Geez

 

[dbleon]

Either there is a hair.. or a nice crack in that axle shaft

 

[tmxmotorsports]

Either there is a hair.. or a nice crack in that axle shaft

Nice eye

 

[4runner2FJ60]

Either there is a hair.. or a nice crack in that axle shaft

Man! I was sure it was cracked after you pointed that out, but got home and went looking. No cracks, but need new outers anyway because the spline wear. My phone camera lens is broken, so it was that or a hair I guess. I would not be surprised though, because this was what the spindle from the same side looks like!

Removed carrier.....good news is the gears look really good, will probably just check out everything and replace the pinion seal and new drive flange. There is internal rust at the brake T bolt hole on top of axle. (a design flaw IMO) A welded on bracket or brake T is much better. Taking @dbbowen 's approach and welding a new Rear brake T to the same spot on the axle the 60 one is located. I'll be fill welding the hole. Wire brushed and letting it sit in a bath of Evapo-rust for a day or so. Removed all the carrier studs to replace with new.

 

[4runner2FJ60]

Cleaning up nicely. For anyone that has not tried Evapo-Rust, I am a huge fan, and would be tempted to say it is the best. Did the soaked wet rag covered in plastic method, one or two more nights of treating and should be good to go.

 

[BurntToast]

Cleaning up nicely. For anyone that has not tried Evapo-Rust, I am a huge fan, and would be tempted to say it is the best. Did the soaked wet rag covered in plastic method, one or two more nights of treating and should be good to go.
View attachment 3746624View attachment 3746625

Evaporust is awesome. I have the 5 gallon bucket and I just drop whatever in there. Next day looks perfect