Builds Hunyuk FZJ80 Build (1 Viewer)

[gearinstalls.com]

The new Nitro 529 and KOYO bearings soon to be put on...

Most of the time the plastic lead filled hammer can tap the tight fitting ring onto the carrier 100% of the way.

This end all done

It's really a good idea to use an oil slinger on these hi-pinions where oil starvation is a possibility. Problem is the heavy duty 29 spline pinions are a fatter pinion and the old 27 spline slingers just won't slip down far enough. Trying to grind it out larger is awkward and time consuming.
While I was doing an unrelated gear search for something else, I happen to run across a 29 spline Toyota part number that works beautifully as shown in the below picture.
27 spline one on top and won't slip down....29 spline one slips on nicely.

 

[gearinstalls.com]

A long time ago I might have used a brass or soft steel "dull" chisel to tap the BIG inner pinion race in.....don't do that anymore. I felt that it affected my pinion preload measurements....made them fluctuate up and down as the torque wrench turned...That never happens to me now so there must be something to it.
I now use a rectangular chunk of steel to offer much better support when I wack it with the hammer.....tapping the race down 80% of the way.
I use a cheapy $1 bubble to make sure it goes down in the hole true and level.

 

[gearinstalls.com]

Then I finish off the last 20% of the journey with an old race.....and chisel it down. That's the closest the chisel gets.

100% seated.

First test paint with a pinion shim of .072".....too too deep. Fairly centered,slight favoring of the heel, but that's not what counts.....it's too deep in the root of the tooth.

Coast side....good placement on the tooth...slight toe....good.

 

[MikePL]

Wow, Zuk? THE ZUK?... It's good to have you here on these forums. Didn't notice you earlier. Love watching your gear installs. Some nice diff porn

 

[gearinstalls.com]

It was 072 for the shim....past experience with these gears means 065 should do the trick (from my un-official cheat sheet which I will post in a moment)


................................ so here's 065 on the DRIVE side.
A slight deep condition(my preferred) and favoring the heel. I prefer it in the center or slight toe but it is what it is. We have no bargaining room with backlash and pinion depth to work with.

065...coast....Nice. Slight toe which is desirable.

Notes for the front 8" install

 

[gearinstalls.com]

Wow, Zuk? THE ZUK?... It's good to have you here on these forums. Didn't notice you earlier. Love watching your gear installs. Some nice diff porn

Hi Mike-
Thanks for the good words.
Yep...ZUK....got the name back in 1990 when I purchased a showroom new Suzuki Samurai that was built up for 4WD magazine. I do have relatives (on mom's side) in Poland....grandma used to send $20 to her sisters/brothers there roughly in 1969. She said that a $20 bill goes a long ways over there with the conditions they have. Grandma passed away in 1985 at the tender age of 83. Her name was Helen Chapuka.

 

[gearinstalls.com]

Here's a summation of some recent TLC gear installs....mostly Nitro
shows the final pinion shim I used and the solid collar total length.

 

[Hunyuk]

You're a busy guy! Glad I caught you when I did!

 

[BVCOTaco]

Sweet build! Can't wait to see this hing on the trails!

 

[Hunyuk]

After getting my thirds back from Zuk, and all the parts to service the front and rear axles from CruiserDan, I started working on putting it back together. While I was cleaning my birfields up I became a little concerned about the pitting in the joint where the bearing contacts it. However, after properly cleaning them up and repacking with grease, they seemed to operate smoothly.

Then got the rear torn apart and completely repacked the wheel bearings and replaced the seals/gaskets.

Unfortunately, this is the point where I got really bad about taking pictures because I was so focused on getting it back together so I could drive it with the new gearing.

 

[Hunyuk]

So, after a few hours working to get it all back together (and not documenting with photos )...I had it ready to roll on the new wheels/tires, but stock suspension.

I was incredibly happy with how the 5.29 gearing turned those big tires. It drives and shifts very smoothly. I was running at about 2700 RPM going 65 on the highway. Thanks Zuk for recommending 5.29! Clearly, it's pretty tight with the stock suspension...so I'll start installing the lift next, just need my springs to arrive from Australia.

 

[msapers]

Nice! Those are the best looking aftermarket wheels I've seen on these trucks.

 

[1973Guppie]

love those wheels! sub'd. I want to get some but can't get past beating up new wheels on the rocks. Maybe when I destroy my stock ones it will be time.

 

[Hunyuk]

Ha, thanks! I know what you mean...I am sure I'll cringe in horror, maybe even shed a tear , the first time I beat them up on the rocks!

 

[Box Rocket]

Good looking stuff. Particularly interesting to see the gear install pics since I'll be doing some Nitro Gear 4.88's right away. Thanks for sharing.

 

[Hunyuk]

Started installing the lift...replaced the two front and one rear frame to axle brake lines. I read somewhere this should take me 20 minues...LOL, apparently I am nowhere near that proficient...

 

[Hunyuk]

Got the bump-stop pucks installed. Getting the DS shock out was insanely difficult. Tried to find a nut-splitter at 2 hardware stores and two automotive stores to no avail. Ended up breaking it loose by turning the shock housing instead of the nut.

 

[Hunyuk]

Wrestled the springs in and got the new shocks installed.

 

[Hunyuk]

Got the front control arms in successfully after a bit of a fiasco

 

[Hunyuk]

Ok, I got really bad with the camera again...and skipped a whole bunch of pictures that I should have taken. Here are the highlights of installing my lift. Did both brake line extensions as well as replaced stock likes with stainless lines at each caliper. I hate brakes...replacing the lines sucked because the 10mm nipples were just a complete pain in the ass. Bleeding wasn't bad after we figured it out...both rear bleeders were completely clogged and had to be thoroughly cleaned out before they could be properly bled.

The biggest challenge of the entire lift installation was replacing the steering dampener. I burned through a ball joint separator (pickle fork) and a ball joint puller tool, neither worked to remove the dampener from the tie rod. We tried heating it with a torch and beat the ever loving crap out of it with a BFH to no avail. Finally, ended up cutting the old dampener off at the ball joint with a grinder. Then the drilling began...burned through 2 cobalt bits and an entire can of WD40, finally managed to break it loose with the 3rd cobalt bit...wish I had video of the damn thing coming out because I was pretty damn excited...took probably 3 hours to get it done.

Removing the other end of the dampener from the frame plate only took one good swing of the BFG with it in the vise.

Double checked all the work...made sure everything was tightened to factory specs and pulled it out of the garage.

Of course a test drive followed including some posing

Now...to carve out some time this week to install the sliders, belly armor and speedo correction.