FJ40 Full Floater Axle Build (IH8C-CLIPS) (1 Viewer)

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Stumpalama

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Well, it didn't take me long to break both stock rear axle shafts after moving up to 37" PBR's.

It's now time to get rid of those c-clips forever and move up to a full floater with chromoly axle shafts.

This thread will detail the process for converting an FJ40 axle to a full floater using @lcwizard 's FF axle brackets, TG studless hubs, FJ60 brake discs and calipers and RCV custom double spline axle shafts.

Step 1: Pull the busted axle shaft and get the axle housing up on the work bench.

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Step 2: Remove the pressed on dust flange from the axle using a steel drift and a ball peen hammer

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Test fitting the spindle mount bracket

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@lcwizard FF bracket:

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I never had a real problem with the C clip concept but sure a FF will add some extra benefits over a SF .. one of these days I will follow your steps ..
 
I've been thinking about doing exactly this on my 40.
sub'd.
 
Paying close attention...
I'm on the fence between this solution or narrowing an FJ80 FF.
 
I considered the 80 and D60 axles but I chose keeping my axle because my diff has 4.56 gears and an ARB installed and the spring perches, wrap bar mounts are already set so I can concentrate on the FF build, not refabbing all my mounts and spending more money on the differential.
 
Agreed. Although the diff is interchangeable on the rear.
 
I just built this same rear end for my 55 and had RVC make some 300m axles. I tried to run the bearings wet the first time out but RCV flanges leaked so I installed seals and now I running the bearings in grease.
Pictures here: Target carrier




Axle drawings,


shaft.jpg
 
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Hi all,

Great to see this project coming to fruition Stump! :beer:

Regards,

Alan
 
Ground off the lip:
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to to get the bracket as far in as possible:

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...and get the face of the bracket face to sit flush with the end of the axle:
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Question, will these axle shafts work in a stock full floating cruiser axle?
 
Next up, ordering axle alignment jigs from Dean at Kick Ass Off-road.

If the @lcwizard flanges index off of the housing then do you need alignment jigs? Seems to me they'd be true as long as the axle is true.
 
They aren't quite THAT tight a fit and I don't necessarily trust the trueness of the axle ends, so just to be 100% sure I ordered alignment pucks from Dean at Kickass Off Road. He is an awesome guy and knows his stuff and took the time to understand my plan. I'm pretty sure he shipped them the same day I talked to him. He's got a couple threads on Pirate and a website, just Google Kickass offroad.
 
are these pucks going to be based on the flanges or the spindles/hubs? what type of shaft are they going to be used on? What are your projected WMS#s?
 
are these pucks going to be based on the flanges or the spindles/hubs? what type of shaft are they going to be used on? What are your projected WMS#s?

I'll answer 2 ways: I am going to align the FF brackets using the spindle (edit for clarity and accurate information: The axle alignment jig will use carrier pucks and spindle pucks) and an alignment bar. The alignment pucks screw onto the spindles. The alignment shaft will be a 1.25" true bar. and the inner axles will be RCV Chromolies. Projected WMS is inside 59", which will keep the rear narrower than the front with 1.25" spacers on the front that were needed for rim spacing.
 
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Are there going to be alignment pucks in the carrier bearings of a third?
 
^^^X2?


my self narrowed fzj80 is at 59 7/8"ish- that is I took 3 1/8" out of it on the right side and stuffed it with a nitro cut to length. I am only on 285s, but I hammered them on a pretty rough 4 mile dirt trail 2 time 5 days a week and there were zero issues with it so far. I didn't know the that the spindle adapters made for such a narrow track; that's friggin awesome. I like the idea of a bolt on spindle over the welded on piece; makes for an easily repairable tube...
 
Are there going to be alignment pucks in the carrier bearings of a third?

Yes. I have a spare 3rd that I will setup and just drop it in and keep it set up in case someone from the club wants to do this after I've figured it all out.
 

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