CRITICAL SAFETY ALERTS

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Front axle right side, check it for cracks. The axle if not repaired can brake on half, and it is common on 80s.
I fixed mine already twice.

Woah, you can't toss out something like this & not either explain better (heck, even if you mean the housing, a welded ear on the housing, etc..)

I've bent the housing, and Christo has a few to his name as well, but nobody has talked about breaking one.

Also, not to go spelling Nazi on you, but in your context & brevity of description, if you meant "break" not "brake" - then where & what "breaks" or are you welding something on your "brakes"?

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.....And when I posted about caliper bolts I did so just as many in the decade-some-plus of being here, I've seen like 5ish posts about people finding missing bolts after working on their 80's (prob were doing FAS/birf work, I don't recall).

My fix for it is I just toss some blue threadlocker on the bolts, and run an extra 5 ft/lbs over spec, then recheck after a couple days /50-75 miles. No issues, calipers been off somewhere short a dozen times or so, maybe more when you include my old bigger LX450, it saw many days of me on my back on cardboard, etc.
 
Hmmm.... if only the poll would allow for a voting process... Again, I think there is a fairly short list of things that can go wrong and threaten your life if it does go wrong... right?
 
Woah, you can't toss out something like this & not either explain better (heck, even if you mean the housing, a welded ear on the housing, etc..)

I've bent the housing, and Christo has a few to his name as well, but nobody has talked about breaking one.

Also, not to go spelling Nazi on you, but in your context & brevity of description, if you meant "break" not "brake" - then where & what "breaks" or are you welding something on your "brakes"?

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.....And when I posted about caliper bolts I did so just as many in the decade-some-plus of being here, I've seen like 5ish posts about people finding missing bolts after working on their 80's (prob were doing FAS/birf work, I don't recall).

My fix for it is I just toss some blue threadlocker on the bolts, and run an extra 5 ft/lbs over spec, then recheck after a couple days /50-75 miles. No issues, calipers been off somewhere short a dozen times or so, maybe more when you include my old bigger LX450, it saw many days of me on my back on cardboard, etc.
Sorry English is not my first language, usually is starts on the ear on the housing. It is a first sign. And if there any crack it is the sign to take the axle off and inspect for cracks all over. Bending housing it is one thing. Driving in harsh conditions causing the axle literally fall apart it is another thing. I have not seen, but couple of 80s owners, my shop knows well, had the axles breaking during driving. I will be visiting the shop today and I will take few pictures.
 
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Here is the picture - not really good picture but gives the idea where to inspect time to time
 
Tugarin: can you describe the conditions, location (in the world), and situation that caused the axle housing in the photo to crack like that? Was the vehicle in an accident, driving on dirt tracks in Mongolia, ---?
 
Axle housing damage is a known issue everywhere else in the world specifically at the front control arm brackets--they shear away from the housing itself.

Happened to my 80 front (nothing like the above picture). Happened to Robbie's 1993.

Toyota upgraded the bracket on the 105 series iterations (that housing is available in the US market). @Cruiserdrew has a new upgraded housing in his 80 series.
 
I used new bolts for my calipers last time they were removed. They're cheap insurance. I also degrease the threaded holes and use red loctite, torque to spec, not 'man tight.' Can't remember the spec offhand, something like 75-80 lbs. It's been a while since I've had calipers off my cruiser.

fwiw the current service manuals for toyota tacoma etc specify that these bolts are not re-useable.
 
Tugarin: can you describe the conditions, location (in the world), and situation that caused the axle housing in the photo to crack like that? Was the vehicle in an accident, driving on dirt tracks in Mongolia, ---?

I drive mostly in rough roads in Central Asia (close to Mongolia :) ) But not close enough. 80s, 105s and other TLCs are most proven vehicles in our conditions. The cracks usually starts as Beno mentioned on the arm brackets - right side the center one. I never heard that some one had problems with left side and very very first sign is the bracket has round notch at the bottom. Crack usually goes from that notch up to the axle itself. Then shear forces will start ripping rear side piece of axle - it causes multiple cracks to develop only after you will see the oil spot.

If this happens no attempts to weld on place or with removed arm. The axle needs to be taken off, strip everything out. And take it to the place where they can scan it with ultrasound and with special solutions to detect invisible cracks.

My first attempt was to weld it on place, did not worked. I took the axle off and welded myself. In spite I thought I welded it good it kept leaking oil. And then I had to take it to the company who weld the gas pipelines and scan it with ultrasound. It showed that the right side of the axle was in web of cracks. So they had to strip brackets, spring mounts etc and do full 3 layer welds all over the right side of the axle. If I would keep driving I would have the same result as on the picture. Though I am thinking of getting a good front axle housing, take it to the same company scan it, strip all the brackets and reinforce it as supposed to. Use 7mm steel to reinforce axle itself, brackets and spring support mounts.

Axle housing damage is a known issue everywhere else in the world specifically at the front control arm brackets--they shear away from the housing itself.

Happened to my 80 front (nothing like the above picture). Happened to Robbie's 1993.

Toyota upgraded the bracket on the 105 series iterations (that housing is available in the US market). @Cruiserdrew has a new upgraded housing in his 80 series.

80 and 105 axles housings are different.
 
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After reading this thread last week had a guy shear the studs this weekend. Looks like two backed out then sheared the others. Luckily it was on a flat section and just veered into the bush. we able to pull 2 from the driver side and get back home safely.
 
After reading this thread last week had a guy shear the studs this weekend. Looks like two backed out then sheared the others. Luckily it was on a flat section and just veered into the bush. we able to pull 2 from the driver side and get back home safely.

Sorry- which studs??
 
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