80 front axle truss & knuckle gusset (1 Viewer)

[40LandCruising]

Couldn't find anything about this,

I've seen the trusses the Aussies make for 80s, but a little hard and pricey to get a hold of state side.

I know pretty much no one trusses 80 axles, but seeing as how mine gets beat and has been off the ground a time or ten, doesn't feel like a bad idea.

I have a minitruck truss I was going to grind on and use, but it's so short it's not even worth it.

I also have minitruck knuckle gussets I might modify to use. But hard to fit them in given the coil bucket Location.

 

[CharlieS]

Pretty sure I've seen weld it yourself precut kits for sale. I'm sure if I saw them, I saw them from here.

If you catch the exchange rate right, buying from Australia can be pretty cost effective.

80/105 LandCruiser - Front Top-Mounted Axle Truss Kit | Rampt Customs

Front Top-Mounted Axle Truss Kit to suit 80/105 LandCruiser. Braces the factory front diff housing to prevent bending under extreme loading conditions, without sacrificing precious ground clearance on the bottom side of the housing. Notably, this kit extends further along the axle housing than...

www.ramptcustoms.com.au

Toyota FJ80 Rear Axle Truss w/ 2.0" or 2.63” MW Upper Links

ballisticfabrication.com

 

[NorthWA]

80 series knuckle gussets — Contact us

The 80 front axle housing is prone to bending (where the knuckle ball meets the axle housing) when you start wheeling hard, especially when you have 37s-40s. Adding a gusset to this section of the housing can give a large improvement in strength and piece of mind. THIS IS A WELD ON KIT. WELDING

www.arcworxs.com

 

[40LandCruising]

Pretty sure I've seen weld it yourself precut kits for sale. I'm sure if I saw them, I saw them from here.

If you catch the exchange rate right, buying from Australia can be pretty cost effective.

80/105 LandCruiser - Front Top-Mounted Axle Truss Kit | Rampt Customs

Front Top-Mounted Axle Truss Kit to suit 80/105 LandCruiser. Braces the factory front diff housing to prevent bending under extreme loading conditions, without sacrificing precious ground clearance on the bottom side of the housing. Notably, this kit extends further along the axle housing than...

www.ramptcustoms.com.au

Toyota FJ80 Rear Axle Truss w/ 2.0" or 2.63” MW Upper Links

ballisticfabrication.com

I've always wondered about how to order from Australia, might have to look into it more. I assumed shipping would be a killer. But if I caught the exchange rate right I could see it working out decent.

 

[40LandCruising]

So after doing some more research, my current plan is to copy @Broski and use 2x4 rectangular tubing and cut it down into a truss.

Then I'll make 2pc lower knuckle gussets out of plate.

 

[Broski]

So after doing some more research, my current plan is to copy @Broski and use 2x4 rectangular tubing and cut it down into a truss.

Then I'll make 2pc lower knuckle gussets out of plate.

View attachment 3940026

If I were to do it again I would use angle iron for the lower knuckle brace and run them all the way over to the control arm mount to help support them.
I would also plate and fully weld the control arm mounts while you’re at it.
Lee @Outsane makes a set if you want to support our local vendors.

 

[JoeCova]

Most trusses are honestly just fancy upper link mounts. Since 80s arent 3/4-linked in the front there isn’t a reason to truss.

Under axle trussing is less desired and thus less common but the only real means of strengthening an axle.

 

[Broski]

Most trusses are honestly just fancy upper link mounts. Since 80s arent 3/4-linked in the front there isn’t a reason to truss.

Under axle trussing is less desired and thus less common but the only real means of strengthening an axle.

I have to disagree!!
There are plenty of bent 80 axle housing out there.
And before I did my truss my front differential bolts would come loose ( common 80 issue ) almost every run causing the diff to leak.
It’s never happened again after trussing.

 

[JoeCova]

I have to disagree!!
There are plenty of bent 80 axle housing out there.
And before I did my truss my front differential bolts would come loose ( common 80 issue ) almost every run causing the diff to leak.
It’s never happened again after trussing.

I’m not saying a housing can’t be bent, I’m just saying what function the vast majority of them serve. I’ve seen plenty of bent trussed axles as well.

If you compare the physics of the force on a truss an under axle truss is night and day difference. The problem is you sacrifice ground clearance.

All my jeeps run trusses, only the Dana 30 gets any real benefit from it.

 

[Broski]

Where not talking about Jeeps here !!

All I’m saying is a 80 axle housing definitely benefits from a trussing if you run big tires and run hard trails.

 

[JoeCova]

Where not talking about Jeeps here !!

All I’m saying is a 80 axle housing definitely benefits from a trussing if you run big tires and run hard trails.

Fair, but thats where 90% of axle trussing occurs, just giving some context.

Good tip on the front diff bolts. I noticed mine come loose from time to time and I have to retorque them on the trail.

 

[alia176]

I built this jig when I did the truss project. You can borrow/rent it, but it's a long drive to NM from SC!!

This post shows how I used it with a scissor jack under the diff area. I also used a true bar for a sanity check.

Might be time for a new axle housing - https://forum.ih8mud.com/threads/might-be-time-for-a-new-axle-housing.1346849/post-15882630

 

[Broski]

I built this jig when I did the truss project. You can borrow/rent it, but it's a long drive to NM from SC!!

This post shows how I used it with a scissor jack under the diff area. I also used a true bar for a sanity check.

Might be time for a new axle housing - https://forum.ih8mud.com/threads/might-be-time-for-a-new-axle-housing.1346849/post-15882630

View attachment 3940149

I did something similar and also used a true bar
All documented in my Build thread.

 

[alia176]

I did something similar and also used a true bar
All documented in my Build thread.

oh yeah, I recall your setup as well. You beat your junk way harder than I do!

 

[alia176]

If I were to do it again I would use angle iron for the lower knuckle brace and run them all the way over to the control arm mount to help support them.
I would also plate and fully weld the control arm mounts while you’re at it.
Lee @Outsane makes a set if you want to support our local vendors.

You mean like this?

Adding a second plate to the control arm mounts then welding that plate to the axle housing AND to the original plate is something that should be done. I have seen folks weld up a second plate just to the control arm brackets only which alleviates the bracket cracking but not the problem that got me going down this rabbit hole in the first place. In my case the bracket ripped the welding off of the axle housing which created a gaping hole on the side of the house and I lost quite a bit of gear oil.

 

[Broski]

You mean like this?

Adding a second plate to the control arm mounts then welding that plate to the axle housing AND to the original plate is something that should be done. I have seen folks weld up a second plate just to the control arm brackets only which alleviates the bracket cracking but not the problem that got me going down this rabbit hole in the first place. In my case the bracket ripped the welding off of the axle housing which created a gaping hole on the side of the house and I lost quite a bit of gear oil.

View attachment 3940227 View attachment 3940228

Yes that's exactly what I mean !! well done.

 

[alia176]

Yes that's exactly what I mean !! well done.

thanks amigo.

 

[40LandCruising]

You mean like this?

Adding a second plate to the control arm mounts then welding that plate to the axle housing AND to the original plate is something that should be done. I have seen folks weld up a second plate just to the control arm brackets only which alleviates the bracket cracking but not the problem that got me going down this rabbit hole in the first place. In my case the bracket ripped the welding off of the axle housing which created a gaping hole on the side of the house and I lost quite a bit of gear oil.

View attachment 3940227 View attachment 3940228

What material did you use for that lower knuckle gusset? That's exactly what I want to do. Just small angle?

I have caster correction plates on my current axle, was planning to swap them to the new housing and weld them. I'm cheap and run them instead of fancy radius arms.

 

[alia176]

I used 3/16" steel every where and bent them on the brake.