'88 4Runner SAS

[John Stw]

Albert performed the final axle prep work while Kyle and I removed the old brackets with a torch and started grinding things smooth.

 

[Volunteer]

Good pics John and it came out great.

 

[John Stw]

With the prep work done Albert started welding in the axle gusset and ball gussets. He used some stitch welds on the top gusset allowing him to only weld a little bit at a time and allowing the axle housing to cool between welds to prevent warping. We used the old knuckle rubber and felt seals along with the knuckles to test fit the ball gussets. With a little bit of grinding and fitting they were welded up.

 

[John Stw]

There was alot of fab work going on, we now understand why professional shops can charge so much. While Albert was welding I was just laying around grinding on the frame.

 

[John Stw]

We used a few hole saws to cut the bushing hole in the frame for the front shackles. There was also something in the frame rail that we cut out with torch and removed with some pliers. Once the holes were cut we installed the provided bushings the way the instructions suggested.

 

[PScottBx]

Swweeeeet. Keep em comin.

me

 

[John Stw]

We then started installing the front hanger. Bolted the axle housing up and checked the shackle angles at different measurements according to hanger position. Decided on installing the hanger a half a inch forward compared to the existing cross brace. We filled in the gap between the hanger and brace with a piece of metal rod and Albert welded the two together. While working on the front end the motor mount covers were welded in also.

 

[John Stw]

Now with the hanger and springs in place we started rebuilding the axle equipped with high steer kit from trail gear. They do not tell you on their web site that you will have to move your steering box, so the experienced team leader saved us some down time there.Thanks to Albert's research the problem with steering box was solved with the IFS steering box bracket kit from trail gear,ordered ahead of time. The shock hoops were also welded up after test fitting the shocks and position check.

 

[John Stw]

With the front almost done we started on the rear lift and relocating the brackets and rear shackle hangers, make sure to test fit and check shackle angles here. We followed the directions and checked but not good enough and we ended up having to add the spare set shackle hangers because the original spot made the rear sit to low. You can see the difference in springs and the need to relocate brackets.

 

[PScottBx]

J,

Great pics.. love to see em.

Tell me... what to you think caused such a different angle from the axle to the DS??? The axles were cut and turned, right??

Did you get the coupler you wanted to fix the issue?

Keep the pix comin



Bx

 

[Doable]

Nice pictures. Hope everything worked out on your 1st outing. How did you like the lower gears with the lockers ?

Did you fell tipsy with the RED DRAGON ? Whats the talk of a milk crate ?

I really like they way the SAS turned out. Man I want to go wheeling after seeing the pictures ya'll posted of Sicily Island.

 

[John Stw]

Everything went fine as far as mechanically, and the suspension worked great. The low gears were just right to me, it pulled pretty strong in 4LO, hoping to have the front shaft problem solved soon.

 

[John Stw]

J,

Great pics.. love to see em.

Tell me... what to you think caused such a different angle from the axle to the DS??? The axles were cut and turned, right??

Did you get the coupler you wanted to fix the issue?

Keep the pix comin



Bx

The harsh angle was caused by the lift and the short distance between the axle and transfer case. Still trying to decide on the method to use to solve this issue, just trying to pick the most affective according to the research. A gear driven doubler would be perfect, but that is last on the list of options.

 

[BikerTrash]

The harsh angle was caused by the lift and the short distance between the axle and transfer case. Still trying to decide on the method to use to solve this issue, just trying to pick the most affective according to the research. A gear driven doubler would be perfect, but that is last on the list of options.

~cough~ Square D-shaft ~cough~

Also check out this link. I had thoguth the problem was they had fabbed your D-shaft to long, I didn't not realise untill last weekend that it was binding because of it being an IFS CV.

Driveshaft CV Modification for Increased Angle

 

[John Stw]

Thanks Josh, its a good idea might have to try it.

 

[BikerTrash]

Thanks Josh, its a good idea might have to try it.

Well the nice thing is if it doesnt work now it is imposible to mess it up right?

 

[locknload]

Yes your IFS CV is the main culprit. Even with the solid axle CV or your clearanced CV your angle will be bad. Here's my 4"TG kit with their long spline DS kit and am '85 CV shaft. This is after one trip to Rausch Creek. I'm running dual cases now which made a the angle much better. So start saving .

You can shorten that DS yourself. Just cut out what you need get some pipe from Lowes (as a conector) center it in your freshly cut ends and weld it up.

My angle before duals, sorry no after shots yet.

 

[John Stw]

Going to try this flange and a single u-joint at the transfer case to fix the drive shaft problem.


http://www.inchwormgear.com/store/product_info.php?products_id=1002

 

[Doable]

Man it sure sounded simpler when we were talking about it. With out looking at the flange would not have thought you could not turn and redrill. . Marlin Crawler stuff for your truck did not show up yet, will call and see whats going on.

 

[John Stw]

It sounded simple, but the stock flange just isn't set up to allow for the new holes.