My answer to the 80 series weak link - all toyota HD front axle (1 Viewer)

[Land Speeder]

In an effort to "upgrade" my rear axle I bought a FullFloat so I could eventually buy Polyperformance axle shafts as well as ARP hub studs and extra dowels. That left a SemiFloat rear 80 series axle and dif in the steel scrap pile mainly because there is ZERO resale market for it. After selling the axle shafts and drum brakes to a friend for spares, it left the carcass. We eyeballed for a mere second before we both said "that could be a front axle". I couldn't get it out of my head for the mere reason that I've busted my R&P and know too many others who wheel lighter than me and have as well. Fast forward 3 months and this is where I am:

9.5" dif with 80-series knuckles

This is as far as I've gotten, but I feel I'm now beyond the "proof of concept" point. I realize I'll catch s*** for this idea, but as it turns out, I'm already catching it from folks that already know. Luckily, more people like the idea than dislike.
I know ruffstuff can make a front 9.5" dif housing, but mine was free, all I needed was a few days in the driveway and a cheap donor front 80 axle. Another friend had a bent housing that had everything I needed... the balls and knuckles!

So, realizing there's a LOT more left to do. And a LOT of money to spend. I don't plan on this axle being under the truck until many months from now. here's how I've gotten to this point so far:

balls cut off

donor axle

figuring where the measurements

it's hot outside... I'll assemble the ball/knuckle for measurements inside:

long side

cut housing to fit:

wow, brown isn't it's color

clearanced the housing to accept the dif on the opposite side

axle shafts seem happy

Painted and balls pressed in!

dif in

still need to align the balls... the "turn" part of a cut-n-turn

front inspection cover that I plan to use flat bolts on

So that's it to this point! The plan is to run longfields, angle the dif at the transfer case and use a double-cardon driveshaft. Also aussielocker, 3-link, hi-steer and hydro assist. Since all that costs a butt-load... it will be a while before you see this under Lorena.
I had a screaming offer on a Dana60 and 14 bolt... but since this was free to this point, I couldn't pass it up. It would be alot more putting the D60/14bolt under there. And quite honestly, the idea of staying all toyota but being beefy was very attractive to me.



stay tuned...

 

[scottryana]

Very cool!

I think the guys at Slee did this with a Diamond Axle Housing.

Ryan

 

[4rnr]

I love it.

That setup has been my goal for sometime. Some day when I have money again. I will be looking to do exactly this. 9.5 center with 80 outers. I love the idea of all toyota. And I don't think ill ever go bigger than 40's on my 4runner. Im pretty sure I can do that with stock 80 shafts...

 

[js93cruiser]

nice! i might go that route because its cheaper, that was a ff rear end correct?

 

[js93cruiser]

oops nevermind its a semi float, would a ff rear work?

 

[Land Speeder]

oops nevermind its a semi float, would a ff rear work?

possibly. But the FF dif cover is welded on the backside and SF have an inspection plate with an identical stud configuration. The simplicity of the SF was that the dif used to be on the front side of the housing. I pulled it and the longer studs, made the necessary groves for the ring, and inserted it on the backside of the housing.

There will not be many of these axles readily available to do this, since most just run the dang thing and never change it out. It was only available 2 full years and 2 more in limited numbers.

 

[js93cruiser]

thats true...i was going to say i have a spare ff rear end i would have traded you! i found a sf rear end on clist for 150...tepting i must say, would you make one for me???? lol

 

[bhmmapping]

Awesome! I can't believe you are actually getting it done. So the knuckle balls fit perfectly in the tubes?

 

[Land Speeder]

thats true...i was going to say i have a spare ff rear end i would have traded you! i found a sf rear end on clist for 150...tepting i must say, would you make one for me???? lol

$150 for a housig and dif? Why wouldn't you?!
it's easy... do it!

Awesome! I can't believe you are actually getting it done. So the knuckle balls fit perfectly in the tubes?

ladies and gentlemen, the guy standing beside me when the gears started turning! bhmmapping!

funny you should ask about the balls fitting... they needed some machining to get into the housing. I could have taken them somewhere, but i just ground them down til they fit. They had to be tapped in... so they're tight, but will still be able to turn like a cut-n-turn.

 

[bhmmapping]

I love it, can't wait to see the finished product. Very clean work so far.

 

[jtaco1]

Very nice. Since you have the ability to use a bolt on front cover now, I would suggest getting a beefier one. I got one from RuffStuff from his original batch to use on my front acle build and it is stupid strong - 3/8" thick. Pretty cheap too, jsut have to call them since they are not on their website. I welded mine on since I used an FJ60 fron axle to build mine.

 

[Land Speeder]

I love it, can't wait to see the finished product. Very clean work so far.

Thanks guys! I like how you said "so far"... as if you know it will eventually be SHE DIRTY. I'm leaning towards the She dirty part...

Very nice. Since you have the ability to use a bolt on front cover now, I would suggest getting a beefier one. I got one from RuffStuff from his original batch to use on my front acle build and it is stupid strong - 3/8" thick. Pretty cheap too, jsut have to call them since they are not on their website. I welded mine on since I used an FJ60 fron axle to build mine.

cool cover! I'm going to try to keep it 'bolt-on' and will definitely be beefing it up. I'm all about trying things first before I buy something else... so we'll see what i come up with.
Did you use 80 series balls? Or 60 series?

 

[jtaco1]

cool cover! I'm going to try to keep it 'bolt-on' and will definitely be beefing it up. I'm all about trying things first before I buy something else... so we'll see what i come up with.
Did you use 80 series balls? Or 60 series?

I hear you on giving the stock cover a shot, no need to spend money when you don't have to.

I would have liked to go with 80 series balls, but figureing out the steering shy'd me away from them so I kept the 60 series balls. It helped since I was able to just swap everything over from the mini truck axle I already had and had been collecting parts for. Best thing is I am wider than a mini truck housing since it is a FJ60/62 housing and also using IFS hub bodies gets me out a bit further, 9.5 diff and all of the mini truck stuff transfers over. Should work well in my 4 Runner.

Keep up the great work, look forward to seeing how this turns out.

 

[IBCRUSN]

Way to go to try something out of the ordinary. I'll certainly be keeping an eye on how it turns out.

For those with deeper pockets take a look at what the HomeGrown crew from CO put together.

The Ultimate Front Toyota Axle

 

[Tapage]

nice .. congrats ..

thought it's more less the same amount of job involved in taking a 60 front, using 80 series knuckles and welding brackes and misc stuff ..

 

[Land Speeder]

nice .. congrats ..

thought it's more less the same amount of job involved in taking a 60 front, using 80 series knuckles and welding brackes and misc stuff ..

The FJ60 front is not wide enough. From what I understand anyway.

 

[handcannon]

Best thing is I am wider than a mini truck housing since it is a FJ60/62 housing and also using IFS hub bodies gets me out a bit further, 9.5 diff and all of the mini truck stuff transfers over.

Bit of a hijack here, but could you give me any info about the IFS hubs and how you set up the brakes? The IFS hubs will set the brake rotor out further, unless you use a spacer. I'm thinking a spacer is a must in order to make the rotor line up with the stock caliper location. You got any pics of what you did?

Thanks
Don

 

[GLTHFJ60]

 

[js93cruiser]

The FJ60 front is not wide enough. From what I understand anyway.

x2 its not, i was going to do the same thing, the long side had to be lengthened 2 ish inches give or take

 

[GLTHFJ60]

Bit of a hijack here, but could you give me any info about the IFS hubs and how you set up the brakes? The IFS hubs will set the brake rotor out further, unless you use a spacer. I'm thinking a spacer is a must in order to make the rotor line up with the stock caliper location. You got any pics of what you did?

Thanks
Don

Sky makes a kit that allows you to use either stock FJ60 rotors, or Tacoma rotors, with 4Runner IFS hubs on a 60/62 series axle housing to make it the same width as an 80 series axle. That affords you the width of an 80 with the strength of a 9.5" differential.
Toyota Wide Axle Kit - Sky's Off-road Design