HELP!! Nasty Birf Carnage BEWARE

[Riad]

Yeah, Dan doesn't need to be there. I just ordered some parts yesterday, I think I talked to a guy name Tom . I think the best way to go is what Cruiserhead05 is suggesting. Get a used axle in good condition and then get the birf kit for the axle. If the used axle is $1200.00 and kit is couple hundreads (can't remember the exact price, it is $320.00 may be), I am thinking within $1700.00 you should be all set, including shipping, "IF" you do the work yourself. Repacking the the birf "properly" might take almost 8 hours for an expert with right tools and about double that for a 1st timer. So I am also skeptical about that $200.00. Good luck and hopefully you get the truck running again soon .

 

[elmariachi]

I think the best way to go is what Cruiserhead05 is suggesting. Get a used axle in good condition and then get the birf kit for the axle. If the used axle is $1200.00 and kit is couple hundreads (can't remember the exact price, it is $320.00 may be), I am thinking within $1700.00 you should be all set, including shipping.

I am still confused by what it is about his existing axle assembly that warrants thoughts of a $1200-1500 replacement?

 

[tucker74]

You guys need to slow down a bit - that doesn't look like spindle damage to me, just grease oozing out of the birf mixed with gear oil. Take the freaking thing apart, clean all the parts, and then see what is actually damaged. Don't give your self a heart attack w/o knowing for sure.

Tucker

BTW: I would not put a used axle on my truck before at least going through it and doing a birf job. You are looking at that expense either way ...

 

[Spydaz]

Oh my darn!! Holy Wheel Bearing Bat Man!

 

[schlopecki]

Any "lessons learned" from the incident?
Taking into account that axles are different between FJ80 and FZJ80, could something like this happen in the FZJ?

I hope I don't sound like a jerk, just want to educate myself.

 

[Riad]

I am still confused by what it is about his existing axle assembly that warrants thoughts of a $1200-1500 replacement?

I am thinking from the worst case scenario. If he discovers after taking the whole thing apart that the axle housing, spindles, knuckles, inner shafts, seals, 3rd member and even the birfs are fine, then I don't see why he shouldn't be fine with just getting the birf pack kit from Dan.

EDIT: forgot about the pads and those 54mm nuts. He might need them too.

 

[elmariachi]

Any "lessons learned" from the incident?
Taking into account that axles are different between FJ80 and FZJ80, could something like this happen in the FZJ?I hope I don't sound like a jerk, just want to educate myself.

That part of the axle (known as the steering knuckle) is virtually identical in all 40, 55, 60 and 80 Series Cruisers, including your FZJ. What appears to have happened is either one or both of the two outer bearing retaining nuts came loose and allowed the hub and bearing assembly to move around on the spindle. It doesn't take much play to casue this, so setting up bearing preload is very important. Toyota devised a simple but effective scheme to hold those two nuts in place via a locking star washer between the two nuts, with tabs that secure each nut and another tab that rides in a groove on the spindle. Those three pieces are designed to hold the hub and wheel in place under proper bearing preload, ensuring many thousand safe and trouble-free miles. In this case the system did what it was supposed to from a safety standpoint. The bearing cratered yet the nuts held the spindle, hub and WHEEL on. Barely. But Toyota had planned that you catch the issue long before this.

Go here post #20 and look at the exploded diagram to see how it all goes together.

One of a couple things could have happened. The outer wheel bearing could have eventually disintegrated from poor maintenance and subsequently allowed enough slop to cause the ensuing damage. Or a faulty prior bearing, steering knuckle or brake service, accompanied by improper setup of the dual nut/locking star washer assembly, could have resulted in the nuts being able to loosen up, allowing the bearing to get hot and crater.

If you want to know how to prevent this on your truck, its simple. First off rebuild the entire assembly using new bearings, seals and gaskets. Second, inspect the knuckles frequently and if you ever enter water, tear them down and check for moisture inside and correct as needed. Third, be prepared to rebuild this assembly every 100-150K miles, depending on type of offroad use and visual inspections for leaks. Lastly, accept that the reason we get a zillion miles out of these trucks is these systems are engineered and designed to be thoroughly maintained. Like an airplane, not like a tricycle.

Edit. He said his truck had 250K miles. He should have been preparing for his second steering knuckle disassembly and inspection project. Even had he replaced all bearings and seals in the process, he'd only been out $300 in parts plus labor.

 

[elmariachi]

I am thinking from the worst case scenario.

Gotcha.

 

[schlopecki]

elmariachi,

Thank you for thorough analysis.
I did not buy FZJ yet, but I'm in the market for one and learning in the mean time.
Actually, a part of my decision for buying the cruiser is, that its construction allows for DIY rebuilds like that.
I've done most of the maintenance for my 4Runner myself since I bought it, but I'm aware, that because of the way it is built,
there are things in it which I won't be able to do myself.

 

[FloridaFJ80]

Ok here are the new pics!!!

 

[ROCKCLMBR 7]

WOW!!!!!!!!!
THat is the dryest wheel bearing i have ever seen! It looks to me like the wheel bearing ran so low on grease and got so hot that it welded itself to the spindle and locked the wheel/ broke the birf loose from the inner axle. Dude, you are very blessed to be here cause if you had lost a wheel you would prob. be toast!
Good luck on the repair it looks worse than it really is. Matt

 

[elmariachi]

Well, now you know, at least on one side. You are very lucky you caught it when you did. It was about to get waaaay worse.

If the truck were mine, I would now pull out that axle shaft, clean up the inside and pull whatever's left of the seal (its just where the ball is welded to the housing.) Look around in there and see of that flailing axle has caused any damage. I'd then disassemble the other side and see what's in there. If there are no visible signs of damage to the housing and the area where that inner seal rests is okay, then I'd get a parts list together:

1. At least one spindle. If you're going to keep the truck, look into new ones from Toyota. Otherwise, maybe cruiserparts.net?

2. Inner and outer bearings for both sides. You can get them from Toyota or find an auto store that sells Timken. You need two of each of these : LM102910, JLM104948, JLM104910, LM102949.

3. All the front knuckle rebuild seals and gaskets from Toyota along with four of the 30304AJR steering knuckle bearings. These go in the top and bottom of the knuckle housing, hard to find aftermarket, best to buy Toyota..

4. Cruiserparts.net may have an axle shaft and birfield. You can also check eBay, there's a guy selling aftermarket birfs for under $100 but you'll still need an axle.

5. Get two quality remanufactured front calipers or buy two from Toyota. I have had good luck finding reman'd Toyota cores from NAPA and others. Also Get 100 Series pads from Toyota.

After all that, get the proper fluids and greases together and get your guy to work.

 

[landtank]

Holy s***, is this that $3500.00 truck I read about? Anyway I'd suspect that the maintenance on the rest of the vehicle will be on par with the front axle. Which means you need to stop driving and start wrenching my friend.

 

[e9999]

wow!

(and don't hang that caliper by the brake line, dude! )

 

[FloridaFJ80]

Landtank - No its not the $3500 FZJ80 I bought, its my other FJ80. Other than the front axle, The truck is in tip top shape... Engine nice and quiet you wouldnt know that damn engine has 265k on it..

WHEN DOES CDAN come back????

 

[landtank]

WHEN DOES CDAN come back????

I think Monday the 8th, but you can call his extension at AM Toyota and get it from there.

 

[CodyRx7]

That'll buff out.

 

[RavenTai]

ouch, kinda hard to tell form the pics but it looks like the wheel bearing cut through the spindle and then the spindle colapsed, the end of the stub shaft looks out of line, is it broken or bent? either way birf is junk, did the inner axle shaft shear or did it just come out of the birf?

 

[Koffer]

Man that truck must have one hell of a sound system and some really cushie seats. Not to hear that or feel that for who knows how long that was self destuction .

 

[DuManchu]

Holy cow!

(words fail me right now)