Affordable regear to 4.30

[Jstawgn]

Edited 6/02/2020

I have successfully run this setup since October 2018 with 255/80R17.
4.30 E-Locker 8" rear diff out of 1999 3rd gen 4runner
4.30 3rd gen Tacoma 4 cylinder front clamshell
With 4.30 and 33" tires it is about 7% under geared which is good since the tire have much higher rolling resistance than stock.

Below is the guide of gear and axle combinations used in our platform.

The rear 8" E-Locker need:
1. Driveshaft flange changed with 27 spline flange with 66x66 mm bolt pattern. (Some later model might come with 29 spline pinion)
2. I added solid spacer since the diff are taken apart anyway.
3. Did carrier bearing preload refresh
4. Two longer stud for E-Locker housings
5. Modify housing to fit the E-locker
6. E-locker harness and switch

The front 8" clamshell need
1. Removal of ADD assembly
2. Reinstall original axle tube from your GX

I was able to complete this swap for about $1K which is very affordable considering you gain lower gearing and rear locking differential.

Most will say this are not strong enough for V8 and 5000 lbs + vehicles. I still consider this much better than the open 8". You gain lower gear which make it easier to turn larger tires and reduce carrier deflection. Also the locker help reduce shock loading when the wheel get off the ground.

 

[Dharma Dude]

2003-2009 GX use the same re-gear and lockers as 2003-2009 4runner, which is 4th gen.
See Gear Package
This is the combo I used for regearing together with ARB lockers for my GX.

So this would suggest 4th gen third members fit and 3rd gen won't.

 

[Jstawgn]

3rd gen 4runner have 7.5" front clamshell.
We need 8" front clamshell.
So the package would not work since for 3rd gen it would contain 7.5" front and 8" rear. While 4th gen need 8" front and rear.

GX is basically 4th gen. The front of 5th generation 4runner, 2nd and 3rd gen Tacoma are 8" clamshell

2nd gen Tacoma never come with 4.30 gear. Only 3rd gen 4 cylinder and MT V6 came with 4.3. This might be the reason nobody tried this combo yet.

 

[Jstawgn]

First snag that I found is the 3rd gen 4runner drive shaft flange is 60x60. 4th generation and up 66x66. Can be drilled or change with new dual drilled flange. The issue is that you supposed to change the crush sleeve since it's one time use needed to maintain proper preload.

Might be good opportunities to change to solid spacer. Solid spacer would need to check pinion depth and play with shim. Which might be to compex to do at home.

Might just take the change to drill the flange on the diff. The driveshaft are hub centered anyway.

 

[danthemanx07]

First snag that I found is the 3rd gen 4runner drive shaft flange is 60x60. 4th generation and up 66x66. Can be drilled or change with new dual drilled flange. The issue is that you supposed to change the crush sleeve since it's one time use needed to maintain proper preload.

Might be good opportunities to change to solid spacer. Solid spacer would need to check pinion depth and play with shim. Which might be to compex to do at home.

Might just take the change to drill the flange on the diff. The driveshaft are hub centered anyway.

This. I think you would drill the flange pretty easily as the driveshaft and the pinion are self centering, but it would still not be plug and play.

Nothing that came with a 8" front came with 4.30s that I have found. About the best that I have been able to figure for a direct swap is the 3.90s that came in some FJ Cruisers. That is not much of a change though.

 

[Jstawgn]

Well I am committed to this. Bought a 3rd gen 4runner 4.30 elocker with ECU, wiring plugs and switch off Craigslist today for $400.

I also bought a 2016 3rd generation Tacoma front differential carrier assembly off ebay last night during the 15% off sale. It's somewhat local so no shipping. Cost $500. Hopefully it's correct 4.30 ratio when I pick it up Friday. Toyota website does show 4.30 for 4wd 4 cylinder and MT V6 model. There are about 7 units listed on Car-part website. Need to ditch the ADD assembly and install the axle tube from the original front diff.

I still need longer stud, elocker gasket, wires to wire the elocker and oil. All in all I am looking right at $1K installed. Doing all the job myself. Hopefully can finish all this in the next couple months.

 

[Jstawgn]

It seems Tacoma guys have been deleting their ADD system successfully using FJ cruiser, V8 4Runner or GX470 parts. So Tacoma 4.30 should not be a problem.

How to: Deleting ADD system

I got the 4.30 front diff delivered yesterday and all look similar beside the ADD tube and actuator. Might be able to recover some money selling this ADD actuator and related parts.

 

[Jstawgn]

Find out the redrill of the differential flange would not work. The outside diameter are too small for 66 x 66 x 11 bolt pattern.

Good thing the flange are cheap.
I think I need 27 spline 66 x 66 flange.Tacoma Output Flange w/Diff Dust Shield
Need a solid spacer Solid Pinion Spacer Kit: V6 to replace the crush sleeve.
Elocker gasket and a couple longer stud to bolt the elocker Toyota Electric E Locker Gasket, Studs, Hardware

I need to buy a 0-30 dial inch pound torque wrench to be able t0 measure the bearing preload. Cheap 0-60 in lbs might be OK but will be much harder to see the scale.

Pinion preload spec are 5-6 inch lbs with used bearing or 12-15 in lbs. with new bearing.

 

[ArBrnSnpr]

Interested to see how this turns out! I'm new to the Toyota/Land Cruiser/Lexus world and I'm trying to get a lift and an e-locker sorted right off the bat.

I picked up a 4.10 e-locker, but I'd sell it in a heart beat for a 4.30 set up. Finding an 8" front IFS diff that's 4.10 is proving to be tough.

If you just so happen to be in the PDX area, I have the inch/lbs torque wrench you need and would love to see your swap.

I'm definitely following your progress!

 

[Jstawgn]

Thanks for the offer. Too bad I am in Ohio. I need to get this soon. Need to measure current preload before I take the old flange off. That would be a good starting point and indicator of how good is the original bearing is.

4.10 front diff are much more widely available. It's used in 4 cylinder tacoma from 05-2015.
They seems to be cheaper than 4.30 that come in 2016 and up tacoma.

Car-part.com list more than 50 available in US.
Hollander parts link below shows a lot of 4.10 front carrier assembly available.
Used 2012 Toyota Tacoma Axle Carrier Assembly Front Axle, 4.10 Ra

 

[ArBrnSnpr]

I thought those were 7.5" fronts???

If they are in deed an 8" that would be awesome!

 

[Jstawgn]

First gen Tacoma and 3rd gen 4runner have 7.5" front clamshell. Second gen Tacoma have 8" clamshell just like GX, FJ and 4th gen and up 4runner.

 

[Jstawgn]

Finally bought 0-30 inch pound dial torque wrench. Really took some time as I do not want to pay more than $50 for it. Bought a bad one from eBay, luckily seller refund 100% and just ask me to throw away the bad torque wrench.

Confirm that my 1999 3rd gen 4 runner came with old style 27 spline pinion gear. Order trail gear "tacoma flange", elocker gasket, longer stud, pinion seal and solid pinion spacer from low range off road.

Need to make the wiring work first before attempting to install the diff.

 

[Jstawgn]

The front is installed with no problem at all. Swap out the ADD housing with the one from the GX.

Finish the flange swap on the rear 8" third member. Installed solid spacer solid Pinion spacer. Reuse all original bearing. They all look good. The elocker came from 99 3rd gen 4runner with 180K miles. The pinion preload is right at 5 in lbs. Backlash at 0.006" checked every other tooth. Gear pattern look pretty good for used gear with 180k miles. Carrier bearing preload was tightened a lot. I move the ring gear side 6 notch to achieve correct backlash. The pinion side was tightened 4 notch to maintain 18-20 in lbs total pinion preload. I cannot believe how light is the preload from factory.

Tomorrow I will start cutting the housing. Hopefully would be done by the weekend.

 

[ArBrnSnpr]

Sweet dude!

Hopefully you can get it all sorted without any more headaches.

 

[Jstawgn]

Got it installed and running. The gear run quiet and cool. Have not driven far yet.

Speedometer is dead on till 50 bit when checked at 65 the vehicle is traveling at 69 mph. Which is strange. it should go the other way. Did tire change calibration on the GPS. Might need to redo calibration and drive at highway speed right away. At 45MPH and 0.76 5th gear ratio indicate correct 1500 RPM for 4.3 gear.

 

[theferg]

Nice job @Jstawgn ! I love to see guys thinking outside the box on this stuff. I am planning an elocker rear in my GX470 as well and nice to see this as a possible option .

Curious on yours and others thoughts on strength of the 8"elocker rear vs. strength of the later 8.2" elocker rear when factoring in the power of the V8...?

 

[James C]

Awesome! Looking forward to hearing how it performs

 

[Jstawgn]

I read somewhere that 8.2 diff can use 8" diff ring and pinion. The strength difference on the gear is very minimal. The biggest difference is the carrier support bridge that reduce carrier deflection.

The biggest thing I learn from doing this project is carrier bearing preload. My OEM 160K diff have lost all its preload. I could move the ring gear with no resistance at all. No wonder some break the diff like it was made of glass.
CBPL refresh
This procedure need to be done on GX that have more than 100k miles.

I put solid Pinion spacer on the 8" elocker. The solid spacer length grew about 0.02" to be able to achieve 5-6 in lbs of torque to rotate the pinion. That means the OEM crush sleeve have collapse a bit. The backlash was a bit much at 0.012". OEM spec is about 0.006-0.011"

I end up tighten the ring side about 8 notch and other side 4 notch to get gear pattern to be good and overall pinion preload 18-20 in lbs.

 

[GXO]

The towers in the 8.2 are the key to being strong than the 8", and that preload is exactly why. The towers can flex and loosen preload in the 8" so unless you rebuild/retighten, they WILL fail. The more you wheel, the looser they get.