fj80 steering box output shaft larger than 60 series, does it matter in a swap? (1 Viewer)

[Infinity00]

I'm going to replace my late fj60 steering box with an 80 box, but my research shows that the 1/1990-1998 fj80 output shaft dia. is bigger - 1.416" vs. the 60s 1.26" diameter (The pre 1/1990 fj80 is 1.26").

Many people have said the 80 series box is a direct swap in to the late 85, but nobody has mentioned the OS size difference as far as I can tell. Sometimes a 91 or 92 is said to work, so I'm a little confused and wanted to get feedback before purchasing something.

Does anyone know if my 60 series pitman arm will go onto the late fj80 box with the bigger diameter? The other specs are identical so I think it might. I don't think I'd be able to use the pitman arm from the 80 box bcs it's too flat, but I'm not sure about that either. Any input will be great...

Specs: fj60
Input spline count: 36
Output spline count: 48
Output shaft dia.: 1.26"
Input shaft dia.: 0.685"
Turns to lock: 4

Specs: 1/1990 - 1998 fj80
Input spline count: 36
Output spline count: 48
Output shaft dia.: 1.416" (pre-1/1990: 1.26")
Input shaft dia.: 0.682"
Turns to lock: 4

 

[bhk]

I have a steering box from a 1997 LX450 sitting in my garage. The splined part of the sector shaft just above the Pitman arm measures 1.25" give or take some goop, same as on my (still installed) 60 box (also with goop). The part number for the sector shaft is the same across all years of 80's production.

In the 80's Forum, the 105 sector shaft is an established upgrade. The splined section on the 105 shaft is larger than on the stock 80 shaft and a new Pitman arm is required. I saw one post from @cruiserdan stating that if you order a new (post production?) 80 box it has the larger shaft and requires the larger Pitman arm.

Where did you come across the 1.416" number? Maybe it was in reference to the 105 sector shaft or updated steering box?

 

[Infinity00]

I found it in the specification for the various years based on remanufactured boxes. I looked at every year and wrote down the specs they provided. Granted, it was off the rock auto website

Thanks for the checking it out for me, it gives me a lot more confidence that I can buy any of those years and likely have it work.

Maybe I can make a call to one of the places that rebuilds them and see what they say...I'll post up if I learn anything new.

 

[GLTHFJ60]

The specs from rockauto are wrong. A stock FJ/FZJ80 sector shaft (output shaft as you call it) is the same spline count, diameter and taper as a FJ60 sector shaft. To that point, you can put a FJ/FZJ80 pitman arm on a FJ60 or FJ62 steering box, or vice-versa. I know because I've done it and am running a FZJ80 steering box on my FJ60 right now. Previously I was running a FJ60/62 steering box with a FJ/FZJ80 pitman arm for quite a few years as well. Before that, a 100% stock setup.

The difference you're seeing may be that the 105 sector shaft, a common upgrade for the FJ/FZJ80 steering box, has a larger diameter and requires a new pitman arm.

Long story short, a stock FJ/FZJ80 steering box is a bolt-in to a FJ60/FJ62.


EDIT: Sorry, realize I pretty much reiterated what @bhk said. He's correct!

 

[bhk]

Long story short, a stock FJ/FZJ80 steering box is a bolt-in to a FJ60/FJ62.

EDIT: Sorry, realize I pretty much reiterated what @bhk said. He's correct!

No problem, good to get confirmation from others!

Can you comment on how "bolt-in" the swap is? I thought I'd seen some posts indicating that the wheel well had to be trimmed slightly and POSSIBLY a steering shaft had to be shortened? I know I saw a post from you about running the FJ/FZJ80 pitman arm on a 60; don't recall if you're running a full 80 steering box.

 

[GLTHFJ60]

Bolt-in is bolt in according to my book. You remove the 60 box, bolt in the 80 box, done. You do have to install the steering shaft to the box before you bolt the box to the frame, but that's it.

I ran a FJ/FZJ80 pitman arm on a FJ60 steering box for a while, that's what I meant. I then had a FZJ80 steering box with a stock sector shaft and stock (80) pitman arm. Now I have a FZJ80 steering box, with a 105 sector shaft and 105 pitman arm, installed in my 60.

 

[bhk]

Bolt-in is bolt in according to my book. You remove the 60 box, bolt in the 80 box, done. You do have to install the steering shaft to the box before you bolt the box to the frame, but that's it.

I ran a FJ/FZJ80 pitman arm on a FJ60 steering box for a while, that's what I meant. I then had a FZJ80 steering box with a stock sector shaft and stock (80) pitman arm. Now I have a FZJ80 steering box, with a 105 sector shaft and 105 pitman arm, installed in my 60.

Good info. Thanks.

 

[Infinity00]

Thank you for the clarification. Helps add to the few threads out there.

 

[DFXR]

This all pertains to late 60 series, right? Not the earlier steering boxes?

 

[Infinity00]

Yup

 

[bhk]

This all pertains to late 60 series, right? Not the earlier steering boxes?

Yes.

 

[Dr. John]

Just wanted to add this for anyone researching this swap. I just swapped a FJ80 box into my late FJ60. I DID have to bend the fender well slightly to clear, but not a big deal. My surprise came when I attempted to install the relay-rod end taper into the FJ80 box Pitman arm. The FJ60 relay rods have larger diameter end tapers than the tie rods (2 mm) and the Pitman arm that came with the FJ80 box has the smaller female taper. Problem solved, of course, by swapping back to the FJ60 Pitman arm. Just odd that other posters have apparently mixed and matched boxes and Pitman arms with no mention of this issue?

 

[Richfj60]

Sorry to hijack the post, but is there an advantage to the 80 steering box over the 60 box? I was going to have my 62 box rebuilt and if there is a reason to go to an 80 box, I am interested in the reason. Thanks.

 

[Jdog]

I just went through this with my 62. The advantages IMO are:
1. Still available sector shaft for 80 boxes
2. Larger power piston
3. Ability to upgrade to 100 sector shaft but also need to change pitman.

In my case, my sector shaft was pitted and no way to insure it wouldn’t leak soon after rebuild. So I got an 80 with warranty.

 

[GLTHFJ60]

Just wanted to add this for anyone researching this swap. I just swapped a FJ80 box into my late FJ60. I DID have to bend the fender well slightly to clear, but not a big deal. My surprise came when I attempted to install the relay-rod end taper into the FJ80 box Pitman arm. The FJ60 relay rods have larger diameter end tapers than the tie rods (2 mm) and the Pitman arm that came with the FJ80 box has the smaller female taper. Problem solved, of course, by swapping back to the FJ60 Pitman arm. Just odd that other posters have apparently mixed and matched boxes and Pitman arms with no mention of this issue?

That's been known for a long time. The reason why people like myself mention the fact that you can put the FJ60 pitman arm on the stock 80 box is specifically BECAUSE the factory FJ60 relay rod end has a larger diameter taper on it. Also a common upgrade for FJ60s is to move to FJ80 style TREs, but that's a topic for another thread.

I just went through this with my 62. The advantages IMO are:
1. Still available sector shaft for 80 boxes
2. Larger power piston
3. Ability to upgrade to 100 sector shaft but also need to change pitman.

Sums it up. The larger power piston = more steering assist.

 

[Adam Scherm]

Jumping on this, but I just found out today from West Texas Offroad, who is rebuilding my 60 series box that the sector shaft has some messed up splines just above where the pitman arm sits.
Can I swap a 80/105 series sector shaft into the body of my 60 series? I’m gonna have em build it up, but I’m just trying to plan for the future, if I need a new 80 series box, or just a new sector shaft.

 

[Jdog]

Jumping on this, but I just found out today from West Texas Offroad, who is rebuilding my 60 series box that the sector shaft has some messed up splines just above where the pitman arm sits.
Can I swap a 80/105 series sector shaft into the body of my 60 series? I’m gonna have em build it up, but I’m just trying to plan for the future, if I need a new 80 series box, or just a new sector shaft.

Nope. If you have a late 60 or 62 you can get an 80 box that will bolt up. That’s what I’m doing.

 

[GLTHFJ60]

X2, nope, can't put an 80 sector shaft into a 60 box.

 

[Adam Scherm]

Thanks @Jdog and @GLTHFJ60 that’s what I figured. I’m just hoping that my rebuilt 62 box will last a while so I don’t have to buy an 80, and have it rebuilt/tapped for Hydro

 

[Jdog]

Thanks @Jdog and @GLTHFJ60 that’s what I figured. I’m just hoping that my rebuilt 62 box will last a while so I don’t have to buy an 80, and have it rebuilt/tapped for Hydro

might start looking for an 80 core. Redhead has rebuilt 80s in stock and can also tap.