'86 FJ60 Driveshaft Yoke Question

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4Cruisers

4Cruisers

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I'm disassembling and cleaning the front and rear driveshafts for my '86 FJ60. The driveshafts have been off the vehicle since the FJ60 was last on the road in 1995 (PO). I was planning on painting the driveshafts and yokes this weekend and reassembling them with new U-joints from Cruiser Outfitters. I got the front driveshaft parts pretty much cleaned up and was getting ready to disassemble the rear driveshaft when I noticed something. The slip yoke on the rear driveshaft has a dish-shaped metal seal in the end near the zerk fitting location, as expected. When I disassembled the front driveshaft earlier this week I thought something looked different - there's no metal seal in the slip yoke. I'm thinking that at some point the PO overfilled the driveshaft with grease and the seal was dislodged by hydraulic pressure. Does that make sense?

Looking at the FSM and the online Toyota parts catalog I don't see that metal seal identified separately. Do I need to find a replacement slip yoke? I sold several of my spares a few years ago, now I wish I would have kept them.

This is from the front driveshaft.

Yoke-1.webp


This is from the rear driveshaft.

Yoke-2.webp
 
Has anyone who's experienced this before fabricated a replacement seal? I imagine it might not be that difficult to make something that would press in tightly and hold.
 
Glad you found something. I did a quick search but my words weren’t exact enough. Reading thru it I see I liked Matts comment and photos of the plug. Clearly I read a lot.
 
Last edited:
The original cap on the front drive shaft yoke has a little flat gap spot to allow air to breathe in & out as the suspension is working. Make sure the new cap can breathe. Maybe drill a small hole in the top of it if it's sealed tight / otherwise it'll blow off again.
 
OSS said:
The original cap on the front drive shaft yoke has a little flat gap spot to allow air to breathe in & out as the suspension is working. Make sure the new cap can breathe. Maybe drill a small hole in the top of it if it's sealed tight / otherwise it'll blow off again.
Click to expand...
Thanks, will do. O'Reilly doesn't show 550-020 available anywhere in their system, so I'm going to try 555-025. They're more like a normal freeze plug. 550-020 is a little larger and is a concave plug, more like the stock plug.
 
Is this info up for adding to the stickies/FAQs, (whatever they’re called now)? Can someone tag Jim K? I’m seriously blanking on his mud name.
 
4Cruisers said:
Thanks, will do. O'Reilly doesn't show 550-020 available anywhere in their system, so I'm going to try 555-025. They're more like a normal freeze plug. 550-020 is a little larger and is a concave plug, more like the stock plug.
Click to expand...
Def followup if the part your getting fits. I’m sure this will be valuable for the future mudders.
 
I went into town and picked up a Dorman 555-025 freeze plug. It's about 1-3/8" diameter so a little loose in the hole - I had to work it a bit to open it up at the lip. I had bought an inexpensive 1" socket for my tap and die tool kit, it has a slightly rounded lip on the rachet end. I placed it over the Dorman plug (cup side up) and beat on it as I rotated the socket around. Eventually got it opened up enough so it wouldn't slip out and shoot across the garage when I put it in the 20-ton shop press. Pressed the 1" socket into the plug, then removed it from the press and tapped the plug off of the socket with a screwdriver and hammer. That opened up the lip so the OD was slightly greater than 36mm. I then tapped it partially into place with a 24mm socket and short 3/4"-drive extension. Back to the shop press and pressed it in most of the rest of the way into the slip yoke. I still had to hammer it home with the 24mm socket. Right now I'm removing the excess lip using my Dremel tool with reinforced cut-off wheel. After I'm done I'll drill a small hole in the center of the plug. I think it'll work fine, just takes a bit of work. Photos tomorrow morning.
 
Headed back out to the garage to hit the plug with the Dremel tool. In the meantime, I went ahead and ordered two of the Dorman 1-7/16" concave expansion plugs on eBay. Almost four times the cost at $3.82 each (free shipping), but O'Reilly doesn't show them available anywhere in their system. I think that would be an easier solution.
 
Good solution!
 
It's all prepped for paint. Other driveshaft components are in various stages of cleaning. Saturday's high is forecast for 70*, first time since early October.
 
The Dorman 550-020 is too small in diameter. I saw conflicting dimensions on the Internet but bought a couple on eBay for a trial. The maximum OD at the top lip is only 1-1/8" or 28.5mm. It looks like the Dorman 555-025 is the best fit.
 
4Cruisers said:
The Dorman 550-020 is too small in diameter. I saw conflicting dimensions on the Internet but bought a couple on eBay for a trial. The maximum OD at the top lip is only 1-1/8" or 28.5mm. It looks like the Dorman 555-025 is the best fit.
Click to expand...

My slip yoke is missing the same front plug. Is the best solution the Dorman 550-025 sized at 1-3/4" diameter? I think this is the same one, although much pricier now:

www.ebay.com

Dorman 550-025 Concave Steel Cup Expansion Plug 1-3/4 In., Height .145 In. 19495550259 | eBay

Find many great new & used options and get the best deals for Dorman 550-025 Concave Steel Cup Expansion Plug 1-3/4 In., Height .145 In. at the best online prices at eBay! Free shipping for many products!
www.ebay.com

Thanks!
 
garfieldthecat said:
My slip yoke is missing the same front plug. Is the best solution the Dorman 550-025 sized at 1-3/4" diameter? I think this is the same one, although much pricier now:

www.ebay.com

Dorman 550-025 Concave Steel Cup Expansion Plug 1-3/4 In., Height .145 In. 19495550259 | eBay

Find many great new & used options and get the best deals for Dorman 550-025 Concave Steel Cup Expansion Plug 1-3/4 In., Height .145 In. at the best online prices at eBay! Free shipping for many products!
www.ebay.com

Thanks!
Click to expand...
Order of magnitude cheaper here:

 
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