Axle swap considerations
- Thread starter archie73
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- Thread starter
- #124
I want to hear more about the 9.5/60 combo. Which 60 outers are you using?
- Thread starter
- #125
Remind me- RS 9.5 will h what steering knuckles?
Mine has Hellfires on it
I want everyone to feel good about themselves
Archie, I used stock kingpin inner C's off ebay, Reid ( Dedenbear) Knuckles, GM 30 spline stuff outside of knuckle , CTM's, custom 4340 inners ( 30 spline ), made seals inside tube at knuckle like Toyota has. Uses 86' K5 stuff for brakes. The inners were the most expensive, like 840 bucks in 2002. The knuckles were a steal, got em on ebay for 350. The CTM's were pricey but Black friday didnt exist back then.
30 spline 
. Next thing you are going to say is what pronoun you want to be called 
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. Next thing you are going to say is what pronoun you want to be called .
- Thread starter
- #130
I wonder if you’d do the KP today with all the SD parts available? I’m not sure I have my head fully wrapped around the hybrid 9.5/60 possibilities. Is it possible to use the RS 9.5 housing and the SD 05 outers. I think there’s a compatibility issues with the 32 spline shafts…
- Thread starter
- #131
You built that axle in the last year, correct? The hellfires aren’t currently available from RS. Is it a matter of being patient until they do another run?
SD is 35 spline. If you are going to spend the money. Don’t try and cheap out when building a custom axle . Trust me you will kick your self for doing so . Yes you can use SD c and Knuckles on a RS housing . The RS housing uses 3.5 inch tubes. If you are dead set on having to use Toyota stuff for what ever reason
. I was myself also once upon a time . Then get a tundra diff 36 spline and 80 balls . I have a RS housing with Tundra diff and. Can show you that diff compared to a 9.5 . 
. If you want the ultimate in strength and clearance. Go with a 9 inch diff and 60 outers . ( what most ultra 4 cars run ) I believe my diff is rated to 1000hp and 40 inch tires . If you plan to go bigger than 40s say 43s and up go straight to a 14 bolt and shave it . And run 40spline .
. I was myself also once upon a time . Then get a tundra diff 36 spline and 80 balls . I have a RS housing with Tundra diff and. Can show you that diff compared to a 9.5 . . If you want the ultimate in strength and clearance. Go with a 9 inch diff and 60 outers . ( what most ultra 4 cars run ) I believe my diff is rated to 1000hp and 40 inch tires . If you plan to go bigger than 40s say 43s and up go straight to a 14 bolt and shave it . And run 40spline .
One can also put in a Gearworks 10" diff in a 9" housing. Lot of racers doing that too. I am not sure how many are running actual 9"? Either way, much better than a toy 9.5" Pinion shaft diameter comes into play, and support, 3 bearings, not just ring gear size.SD is 35 spline. If you are going to spend the money. Don’t try and cheap out when building a custom axle . Trust me you will kick your self for doing so . Yes you can use SD c and Knuckles on a RS housing . The RS housing uses 3.5 inch tubes. If you are dead set on having to use Toyota stuff for what ever reason
Yeah I called them and waited for some to become available. All money in with everything, I'm just building 609s next and moving my current axles to another project
- Thread starter
- #136
So I was hoping others in my boat would chime in, but in their absence I’ll continue on my line of thought:
Am I over thinking the added complexity of using 60 over 9.5 axles? Mike, Matzell or anyone who have linked a Dana, or even a 14b, under 4x series frame- how bad was packaging? Would an LC axle been easier? If I go SD 60, it seems the cast portion needs to be trimmed back in order to have a place land the links. Additionally, I’ll be narrowing the axles to 63-65”. I think I understand this and it seems doable, if a bit tedious.
As much as I want to be a cool kid, I don’t realistically see me swinging a hybrid/custom axle. Seems like you need to buy two or three to make one. I started this thread with the intent of using a junkyard deal and will likely stay this course.
Am I over thinking the added complexity of using 60 over 9.5 axles? Mike, Matzell or anyone who have linked a Dana, or even a 14b, under 4x series frame- how bad was packaging? Would an LC axle been easier? If I go SD 60, it seems the cast portion needs to be trimmed back in order to have a place land the links. Additionally, I’ll be narrowing the axles to 63-65”. I think I understand this and it seems doable, if a bit tedious.
As much as I want to be a cool kid, I don’t realistically see me swinging a hybrid/custom axle. Seems like you need to buy two or three to make one. I started this thread with the intent of using a junkyard deal and will likely stay this course.
When I narrow an axle. I simply. Either cut the C off and then the tube. Set caster angle and weld back on. Send axle shaft to Moser and they will cut and respline. Branik will make you a custom axle.
If you are doing HP D60 driver drop, maybe we should alk. I have one made to 64.5" wms and custom shafts.
If you are doing HP D60 driver drop, maybe we should alk. I have one made to 64.5" wms and custom shafts.
Archie, specific answer is to link front or rear with a 40 frame and 40 width axles you have to section frame for towers & CO's or use coils & shocks. The options to stay Toyota and get width is to use 60 or 80 axles, this allows not having to inboard coil over towers soo much. You asked about build up of an axle, the 40, 60, or 80 have IMO a weakness at the diff. Axles, steering, knuckles can all be dealt with. So you want to link and sounds like want a stronger diff. If linking you are cleaning and welding brackets to an axle, find a 60 with 4.10's ( marketplace ) , clean it, locker it, narrow it, I link kingpin 60's, use 86 K5 stuff for rotors & brakes, grab some 6 lug hubs ( solid axle ), WFO sells a flange for the 60 that has all 3 LC patterns drilled for dline. I've thought thru all the paths to get there, using 60 axles to have dlines, steering, brakes all bolt up, MEH, still got 9.5 diff, using 80 axles, available and good but same end result. What convinced me was opening the 60 and 9.5 side by side, one look at the cross shaft in the diff and your sold, no more 9.5. Although I built a hybrid 9.5 diff with dana 60 outers for the front and it has lived.
I think some of you have seen this....
irate4x4.com
FJ80/FZJ80 axle thread
I've had 1 or both of these axles in every wheeler I've owned since about 06, so I figured I share my experience. Plus add all the info in one place. These often get lumped in with mini trucks when talking Toyota axles, but I feel they are different enough, it's worth discussing. Birfs for...
irate4x4.com