My 100 Series Carnage

[NCFJ]

The FJC came with the 8" ring in the rear and was fast proven to be inadequate for the job and they bumped up to an 8.2" I have since read a couple other posts refering to the early 100 front axles not holding well under extreme conditions. All vehicles have their weak points, unfortunately you found yours. I blew the R&P on Daniel in my FJC which led to the diff locking up and then snapping the T-case output shaft.

Toyota bought me a new T-case, drive shaft and complete 3rd with locker. I drove it home 200 miles in front wheel drive with a plastic cup duct taped into the rear output of the T-case.

 

[CharlestonG8R]

The tough part is that it's difficult to drop that kind of news on someone who intends to drive home with the broken truck, know what I mean? It's real tough to dash hopes (for an easy repair) like that.

Any pics of the freshly rebuilt diff before installation?

Johnny, you are the man. Next time you see me with damage where driving home looks unlikely, just tell me and I'm good I trust your judgment. If I hadn't been an idiot and left my meds at home, I would've stayed overnight and wheeled as a passenger on Sunday. I still haven't gone for a ride in Moonshine! Oh, and don't worry, I won't ever remind you that I'm aroused by your passion for removing lug nuts!

The new differential came in as an assembly, I have a picture of that? It's not terribly exciting - I have the old differential in the back of the truck. Which reminds me: I should take it out before my Bed, Bath, and Beyond fragrance is overpowered by the smell of gear oil...

 

[CharlestonG8R]

I drove it home 200 miles in front wheel drive with a plastic cup duct taped into the rear output of the T-case.

That's pretty dang motivating, right there! Glad to hear that Toyota stepped up and replaced it for you. I would've thought that wheeling would've voided the warranty.

 

[NCFJ]

Oh they tried to void the warranty. Every bit of advertising for that vehicle showed it being used off road, not one soccer mom picking up the kids. Pictures and text. The ring gear was a known issue at Toyota and I knew this. I also spent a fair amount of time on the trail with their own trail team. I had to go to corporate Toyota USA to get it fixed. I mentioned to them how negative press on places like FJCruiserForums.com would really not bode well for them as the ring gear was at that time known but no TSB on it.

 

[elkaholic]

Red solo cup gets two thumbs up. The reamed out drive flanges have one condition attached .... they have to be smooth to keep from damaging the axle splines.

Agree - the ones I have seem were reamed out to the point that the dust cap did not have anything to bite on and a small metal strap was used from one stud to one opposite to hold it on ...

 

[GarnerFJ40]

Should keep the broken parts and add to a new trail carnage award...

 

[CharlestonG8R]

Should keep the broken parts and add to a new trail carnage award...

Sure, I can use it for Logan's Run next year if yall want? The diff is freakin heavy!!!