"It's Basically a Land Cruiser" Swapping a 9.5" LC100 rear end into a GX470

[PerryParts]

Hey folks!

I wanted to share a DIY project that I did on my GX. While down at Cruisers on the rocks, I blew up my fourth 8" rear end in the GX.

Chatting with some of the other guys there, we came up with the idea that I'd try and squeeze the 9.5" rear end from an LC100 into the GX. They're really good folks down there, a few guys hooked me up with gears, and another sold me a 9.5 axle for just $200. Great people.

Overall, if you're diligent about measurement, and you have an angle grinder and a MIG welder, it's not a bad job.

Basically what I ended up doing was cutting the tubes off the 8.0, so I could keep the ABS sensors and tone rings, spring perches, control arm mounts, and axle shafts.
Then, I cut out the pumpkin from the 9.5, sleeved it, and welded it into the center of the old 8.0. Used a 30 spline lunchbox locker for an 80 series to interface the whole 3rd member with the 30 spline GX axles.

What I ended up with was a 8.0/9.5 hybrid, that bolts right up into the stock location. It's 3 linked so it adds some extra clearance by the gas tank since there's no upper link there. So far it's working great. At 4 trips out, and about 1200 miles on it now.

Full write up on my blog, with measurements, tips and tricks, etc, but I also dropped in some images here as well.

https://www.perryparts.com/post/putting-a-9-5-rear-axle-in-a-gx470

 

[Mrpinortiner]

Nice work.

 

[Rednexus]

Very interesting writeup as well! Looks to be potentially within my skill range, though at the upper end of it. I may consider this in lieu of an 8.2 swap as it would be about the same price.

 

[HomersCanyonero]

Wow…nice work. And what did you do with the front gears?

 

[PerryParts]

Wow…nice work. And what did you do with the front gears?

I picked up a set of 4.10 gears from ECGS, I think it was $350 shipped.

 

[Poop Bubbles]

Why stop there? Get a Tundra 10.5".

 

[PerryParts]

Why stop there? Get a Tundra 10.5".

I’m putting portals on in spring, no reason to go beefier as the portals are geared down 25%, reducing the load on the rear end. The 9.5 is more than enough for the GX application, and preserves more ground clearance

 

[Mike NXP]

Thats pretty awesome, nice work. You make it looks easy.

So out of curiosity, at this point what would make the powertrain different on the 100 series compared to your modified GX? Do the platforms share the same transmission / transfer case as well or are they different too?

 

[PerryParts]

Thats pretty awesome, nice work. You make it looks easy.

So out of curiosity, at this point what would make the powertrain different on the 100 series compared to your modified GX? Do the platforms share the same transmission / transfer case as well or are they different too?

I know that the front diff is different (because I tried to use the 4.10 front gears from the LC in the GX Clamshell)
From what I've read, the GX front clamshell style diff is stronger than the LC. After being inside both, I'd agree. The carrier is one piece instead of bolted together, and the clamshell has a lot more material in the way of the ring and pinion separating, as opposed to the 3rd member style on the LC.
Driveshafts are 1/2" different in length, spline count, and flanges are the same. GX driveshaft has a larger OD so I ran that.
No idea on the Tcase, but I've yet to see a GX Tcase blown up!

 

[Rednexus]

I know that the front diff is different (because I tried to use the 4.10 front gears from the LC in the GX Clamshell)
From what I've read, the GX front clamshell style diff is stronger than the LC. After being inside both, I'd agree. The carrier is one piece instead of bolted together, and the clamshell has a lot more material in the way of the ring and pinion separating, as opposed to the 3rd member style on the LC.
Driveshafts are 1/2" different in length, spline count, and flanges are the same. GX driveshaft has a larger OD so I ran that.
No idea on the Tcase, but I've yet to see a GX Tcase blown up!

I am pretty sure they use a different T-case. I agree that the GX T-case and front diff are plenty robust, along with the front and rear driveshafts.

One question on your mod: Is there a potentially for gear oil to get trapped in the axle tubes due to the metal alignment sleeve? I would be concerned that impacted gear oil and/or debris might accumulate in this are (due to the sleeve preventing drainback) which could shorten wheel bearing life. Without the sleeve it would in theory freely flow to the 3rd member and come out at differential fluid change. Or is there another way to get the gear oil to make it back out?

I'm probably leaning 8.2 swap. But, on paper, this is a cheaper mod and is stronger than an 8.2. I would probably build a 2nd upper link bracket to keep the OEM 4-link as my rig gets a lot of highway/tow miles. And this would allow the use of 4.30 gears, which aren't available for the 8.2.