could I put the original diffs back in the 60 housing? (where is the coarse spline?) is there a difference in the early diffs part where the axels go into them vs the later diffs?
yes, you can put your diff in the 60 housing. yours will have the fine spline side gears, it will just be a course pinion. you will be able to use your original driveshaft with your old diff. if you go to the 60 diff, you would have to swap the slipshafts on the driveshaft because the bolt pattern on the flanges is different.
if I were to keep the stock axel housing, can you put a disc brake knuckle on and retain the original birfields/lockouts?
yes, you could. you're damned if you do, damned if you don't. you have course birfs which arent' strong, but to change birf/hubs, you'd get fine, but they'd be the oddball long birfs.
I could keep stock axel housing, put in an fj62 or mini truck disc brake conversion, possibly keeping the weaker birfields/diff but not have an emergency brake
e brake will only be affected by the rear axle, so doing disc in front has no bearing there. if you go 60/mini, you will have issues with the steering arm. the size/taper of the tie rod ends may not work and you'll have to see what others have done. i wouldn't keep the course birfs if you have 60/mini stuff, because that is the larger (stronger), fine spline (stronger), short/common birf. much better option than course.
I could switch out to the fj60 axels retaining the stronger birfields/diff, gaining 3" width and getting an ebrake,,,
you will still have to do some mods to get the axle mount e brake to work, but effectively yes.
either way I could also take the longer birfields off my 78 (with the warn hubs) and put the stronger mini truck birfields/hubs on my 78... but I am not sure the 55 or 60 axels will go into the 78 birfields,
the axles will mount to the birfs. the 60 long axle is longer than the 40/55, so it will only work in a 60 housing. the only thing you would have to do on your 55 housing is minor grinding to the top and bottom of the ball ends where the 60/mini birf would slide in
I think there are going to be some Tie rod/TRE issues with all these mixed pieces, anyone know? ,
Yes, fj60 are much larger, iirc, mini is a bit smaller. it's been figured out..look at the tech section.