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- #161
Rear axle in, made some new bump stop mounting plates, and wheel speed sensor cover plates.
Build Klip's FJ62 revival
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- #162
Installed the brakes, made new brake lines and mounting tabs, installed fzj80 park brake cable. I bought the RuffStuff side mount shock mounts but they weren’t long enough so I made some similar to the RuffStuff design and got them welded on. Gonna do a little sanding and squirt some paint on it. Rear is pretty much done. Drive shafts are at the shop down the road, thankfully he rebuilt after the fire and has been up and running for about a year now. Also pondering rear sway bar options.
Modified the lever for the lspv, gonna give this a go.
Ha! Yes that’s a mini fj40 in the background!
Modified the lever for the lspv, gonna give this a go.
Ha! Yes that’s a mini fj40 in the background!
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- #163
Back on all 4
But that didn’t last long, ready to tear down the front. Gears, locker, big brakes, re bush the leafs, new shocks and shock towers. Not decided on shock towers yet but the originals are definitely coming off.
But that didn’t last long, ready to tear down the front. Gears, locker, big brakes, re bush the leafs, new shocks and shock towers. Not decided on shock towers yet but the originals are definitely coming off.
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- #164
Got the front disassembled, I think this is the first time in its life the front diff has been removed. And it’s been sitting a while, there’s a defining line of where the oil level was. A lot of cleaning ahead…
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- #165
Front 3rd is ready to go back in. This one set up way better than the rear. 5.29, ARB. Still need to do a little cleaning on the housing.
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- #166
Got the front diff installed, big inspection plug welded in, and shock mounts welded on. I went back and forth on which shock mounts to use. I bought the shock mount kit from marlin that had the steering stop gussets built in, but they didn’t fit. Then I got the trail gear knuckle ball gusset/shock mount kit which fit ok I just didn’t like them that much. I ended up modifying the marlin mounts.
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- #167
Mocked up a shock. Towers are out, gonna bend up some hoops.
Brought some parts in
Also did a very rough mock up of the brakes to see what I’m getting in to.
Definitely adding more thread to the caliper mounting holes on the brackets. Brainstorming on the brake lines from the axle to the calipers. I need to make new brakes lines on the axle also. These brakes are huge! Pretty stoked to finally install them!
Brought some parts in
Also did a very rough mock up of the brakes to see what I’m getting in to.
Definitely adding more thread to the caliper mounting holes on the brackets. Brainstorming on the brake lines from the axle to the calipers. I need to make new brakes lines on the axle also. These brakes are huge! Pretty stoked to finally install them!
That adapter ring over the spindle is for mounting those calipers? Trying top wrap my head around what I'm looking at here haha.Mocked up a shock. Towers are out, gonna bend up some hoops.
View attachment 4134407
Brought some parts in
View attachment 4134408
Also did a very rough mock up of the brakes to see what I’m getting in to.
View attachment 4134409
Definitely adding more thread to the caliper mounting holes on the brackets. Brainstorming on the brake lines from the axle to the calipers. I need to make new brakes lines on the axle also. These brakes are huge! Pretty stoked to finally install them!
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- #169
Yessir, this is the FROR big brake kit. 2017 and newer 4 runner front disc brakes.
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- #170
I wasn’t really feeling like pounding bearings and wheel studs in the hubs Friday night. So I worked on mounting the arb compressor. In searching for a mounting spot I discovered something pretty neat. The two bolt holes circled with sharpie on the inside of the fender is the same bolt spacing as the arb compressor 
. I don’t recall what was there (if anything?) but it is in the area that I wanted to mount the compressor so I went for it.
Using the mounting plate that came with the compressor. It feels pretty solid, should work well.
. I don’t recall what was there (if anything?) but it is in the area that I wanted to mount the compressor so I went for it. Using the mounting plate that came with the compressor. It feels pretty solid, should work well.
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- #171
On Saturday I made some threaded bosses for the caliper brackets and got them welded on. Also pressed the bearing races and wheel studs in the hubs.
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- #172
Here is a better mock up picture. With the caliper mounted I was able to get a better idea of what I need to do for brake lines.
To install the hub dust seal the bent up flange must be modified and the seal needs to be turned around. I cut the flange completely off.
@Mike Shull, here’s an example of how handy this swag band saw table can be. Made quick work of cutting the seal flange off.
I also cut the caliper bracket spacer off of the bracket and sanded the tack welds off. For final assembly I put a thin layer of loctite anaerobic on both sides of the spacer, gasket on the spindle and dust seal like the parts picture shows.
I also installed the spindle with class 10.9 flange bolts. I used 10x1.25x40mm bolts.
To install the hub dust seal the bent up flange must be modified and the seal needs to be turned around. I cut the flange completely off.
@Mike Shull, here’s an example of how handy this swag band saw table can be. Made quick work of cutting the seal flange off.
I also cut the caliper bracket spacer off of the bracket and sanded the tack welds off. For final assembly I put a thin layer of loctite anaerobic on both sides of the spacer, gasket on the spindle and dust seal like the parts picture shows.
I also installed the spindle with class 10.9 flange bolts. I used 10x1.25x40mm bolts.
Sweet! Now I need to think of a modification that I can do to justify getting one of these handy saws.
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- #174
Made the right side brake line on the axle.
Looking for the soft lines from the axle to the knuckle. The 96+ 4Runner front brake lines looked close so I ordered the cheapest set I could find for mock up purposes. It’s a little tight so if I get the extended lines I think they’ll work. Mock up of roughly where it’ll land. Then make brackets for each end.
Looking for the soft lines from the axle to the knuckle. The 96+ 4Runner front brake lines looked close so I ordered the cheapest set I could find for mock up purposes. It’s a little tight so if I get the extended lines I think they’ll work. Mock up of roughly where it’ll land. Then make brackets for each end.
Interested in seeing what you do with brackets. The stock ones with the little flat spring clip are awful. Every time I do anything with brake lines (or the clutch hose) I struggle. There has to be a better way.
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- #176
Got the brake lines in and made some mounting brackets. I made them pretty long to cut to fit. @CruiserTrash , kinda at the mercy of brake line manufacturers for the mounting style. Unless you go with AN fittings you’d be able to use a bulkhead fitting which would be pretty stout. I cut my brackets to fit the brake lines I got.
This should be enough parts to keep me busy for the weekend.
I made a die to press a bead in the bracket to add some rigidity and hopefully eliminate any doingyness. 14 gauge sheet metal was the perfect thickness for these brake lines.
Couldn’t ask for a better fit!
This should be enough parts to keep me busy for the weekend.
I made a die to press a bead in the bracket to add some rigidity and hopefully eliminate any doingyness. 14 gauge sheet metal was the perfect thickness for these brake lines.
Couldn’t ask for a better fit!
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- #177
Brake lines are done. I don’t like the gold clips these brake lines came with, they’re loose when clipped on. I’m going to use e clips. Now it’s time to paint!
These are the extended brake lines for the front of a 96 and newer 4 runner from SRQ. 14.5” overall length.
These are the extended brake lines for the front of a 96 and newer 4 runner from SRQ. 14.5” overall length.
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- #178
Paint is still tacky but I had a little time this morning so I went for it…
Still trying to figure out the orientation for the brake pad spring clip. The clip seems incorrect, gotta look into that.
Still trying to figure out the orientation for the brake pad spring clip. The clip seems incorrect, gotta look into that.
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- #179
When I installed my drive shaft I noticed a gap between the t case flange and the drive shaft. Took it back off to inspect and found burrs where the studs were pressed through. Same with the front t case flange. Both are new, I didn’t noticed the burrs when I installed them. I removed both flanges, going to take them apart and reassemble. It’s never fun removing new parts you just installed but this would definitely cause problems.
I tried to cut them off with a carbide scraper and some taps of a hammer, that was a no go.
I tried to cut them off with a carbide scraper and some taps of a hammer, that was a no go.
That sucks! These are brand new flanges??