Achilles heels of the 55 (ADVICE NEEDED)

[DanTCook]

Greetings!

I was speaking with some knowledgeable 55 folks the other day about the weak points of the Pig. They explained that the 55 was Toyota's first attempt at a wagon and, therefore, inherently had some spots that needed improvement in subsequent iterations. I guess this is all pretty intuitive.

They identified the following:

1. The door hinge attachments...or more accurately, the sheet metal where the hinges are attached, is just that....sheet metal.....and is therefore prone to metal fatigue and eventual failure.

2. The door plate locking mechanism should be upgraded to the FJ60 style....something about the 55 has a wheel to capture the post vs. an arm to capture a bar (I was driving so the details are probably not accurate).

3. I know the tailgate glass motor and assembly can be finicky.


If you have insight on this topic, please advise. We would like to address (to the extent that we can) any problematic areas that MUD members can help us identify BEFORE we end up in the middle of nowhere with an issue......like doors falling off or flying open, etc.

Thanks in advance for your help!

Dan

 

[bobm]

If you look at @scrapdaddy build Slow 71 he did eccellent repairs on the 1st two things you mentioned and others have followed suit!! Tailgate motor a lot of us found bypassing the safety switch resolves being finicky, its the gear that is problematic cause of cracking. New gears can be bought at Shapeways. If i had an ounce of patience i would have looke up the posts for you. I dont. Sorry

 

[DanTCook]

Great. I’ll look it up! Thanks

 

[scrapdaddy]

Dan,

You'll spend three weeks trying to find something in my thread. Here's what I did because they were cracked on the door. I think the body side mounting is good. Not all of them crack, but it might be good insurance to beef up.

Grind it all down and weld up any cracks...

Make a plate to fit...

Weld it all up..

And grind it smooth..

Not a pro job, but has held up so far.

 

[scrapdaddy]

Dan,

Your build is somewhat different than most of ours being a world trip vehicle. That said, a lot of the guys here have learned what works and what doesn't. I hope you don't mind when we throw out some ideas or opinions ( we'll probably do it anyway ). Like Bob said get those gears and rebuild the motor. Personally, I'd throw away all the wagon's wiring and start over for a new beginning.

I've never heard of anyone upgrading to 60 door latches, but a couple guys have switched to "bear claw" type which seem to work good.

Something else I'd consider is a full float rear axle. She's going to be heavy and having a newer/stronger motor, snapping an axle might be a real concern.

 

[DanTCook]

Thanks for all the information, guidance and photos.

I have the Shapeways white plastic gear and will rebuild the assembly using it. Has anyone found the need to upgrade to the steel or aluminum? I'll probably rebuild 2 motors so I have a spare. Having an operational rear window is kinda important for our set-up.

I thought about a full float as well, but at the time we were sourcing the axels a FF was hard to find. I talked to Ruff Stuff and they were not producing their axel housings at that time.

I guess we will just have to wait 'n see on some stuff.

I really appreciate your feedback.

 

[scrapdaddy]

Here's who I used, cut to FJ60 width, matches my front axle.

Diamond Axle Housings

Buy highly durable and great strength toyota fj80 axles. Our axle housings are available in custom sizes with custom configurations. Get the best deal now.

frontrangeoffroadfab.com

 

[Godwin]

Something else I'd consider is a full float rear axle. She's going to be heavy and having a newer/stronger motor, snapping an axle might be a real concern.

My 60 is heavy and I went with a FF not because of snapping an axle but because I'd lost a semi-float rear bearing that only had ca. 50k miles on it. Replacing rear wheel bearings on a semi-float Cruiser axle is an all day job with pulling the differential, axle shafts, etc., plus the bearing often has to be ordered. Use the right FF axle and FR and RR wheel bearings and hub seals may be interchangable and available at many parts stores.

 

[scrapdaddy]

Good point Jim. Traveling around the world making everything easier to repair is I'd imagine high on the list.

 

[gonzopancho]

I’d carry a spare plastic gear rather than run brass.

 

[PabloCruise]

They explained that the 55 was Toyota's first attempt at a wagon and, therefore, inherently had some spots that needed improvement in subsequent iterations.

The 45LV was there before the Pig. A little different, being somewhat 40-based, but technically a wagon...

 

[greenbeast]

The 45LV was there before the Pig. A little different, being somewhat 40-based, but technically a wagon...

Funny @gonzopancho were just discussing this very reality.

 

[gonzopancho]

The 45LV was there before the Pig. A little different, being somewhat 40-based, but technically a wagon...

IMO, the only substantial thing that makes the 45lv “somewhat 40-based” is the Gifu produced body from the firewall back.

Otherwise it’s a 40-series.

 

[gonzopancho]

The door plate locking mechanism should be upgraded to the FJ60 style....something about the 55 has a wheel to capture the post vs. an arm to capture a bar (I was driving so the details are probably not accurate).

Seems like a lot of work internal to the door.

 

[scrapdaddy]

I’d carry a spare plastic gear rather than run brass.

What's your reasoning behind this? A wear problem with brass on brass? I always felt the amount of use the tailgate gear got, it wouldn't matter much unless there's something I'm missing.

 

[gonzopancho]

What's your reasoning behind this? A wear problem with brass on brass? I always felt the amount of use the tailgate gear got, it wouldn't matter much unless there's something I'm missing.

I’d rather break / strip the plastic gear than burn the motor or strip both gears.

 

[scrapdaddy]

Got cha !

 

[LAMBCRUSHER]

Dan,

You'll spend three weeks trying to find something in my thread. Here's what I did because they were cracked on the door. I think the body side mounting is good. Not all of them crack, but it might be good insurance to beef up.

Grind it all down and weld up any cracks...
View attachment 3134267


Make a plate to fit...
View attachment 3134270


Weld it all up..
View attachment 3134271

And grind it smooth..
View attachment 3134272

Not a pro job, but has held up so far.

I can think of worse ways to spend 3 weeks!!! Besides, it only took me 3 hours to find all your power steering good info.

 

[LAMBCRUSHER]

Thanks for all the information, guidance and photos.

I have the Shapeways white plastic gear and will rebuild the assembly using it. Has anyone found the need to upgrade to the steel or aluminum? I'll probably rebuild 2 motors so I have a spare.

get a spare plastic gear. as stated above, if you use the steel gear, and have binding issues, the steel gear will transfer the problem, and possibly cause more damage.

A couple areas I keep forgetting are sore subjects to these pigs are their radiators, and windshields.

I don't have solutions for these; only offer them as further challenges.

Cheers!

 

[DanTCook]

Thanks for pointing out additional problem areas.

Speaking of steering.......does anyone have a recommendation for a crossover steering set up or a link to previous discussions?

Thanks for all your help.