Opinions on a 9.5 Front Axle Build. Worth It?

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akarilo

akarilo

Joined
Jan 19, 2006
Threads
254
Messages
2,013
Location
Tulsa, OK
Website
www.cardomain.com
OK, I've had an FJ62 with aussies front and rear on 33" TSL's that saw its fair share of rocks. I have since moved on to a '97 LX, e-lock, 37's, Nitro 5.29's, Longfields, Marlin T-case gears, etc. Problem is, I can't keep the front diff together. I've broken/ chipped the ring gear for a third time now, the last of wjich was cryo'd, solid collar, set up by ZUK. The stock inner shafts have never given out, but the ring gear apparently just can't take it. I do wheel on difficult obstacles but no bouncing or thrashing of any sort IMO.

I'm seriously considering a 9.5 up front and hoping this will solve the issues I'm having. Some say that the "coast" side of a low pinion up front is about 20% weaker than the drive side, leaving me to wonder if it's any stronger than the high pinion 8" that currently likes to implode. This got me to thinking that Toyota ran a 9.5 up front for a long time, and it seemed to work fine.

My question is: Who's running 36/37's (or bigger) on a low geared 60 (or 40) that has not had any/ many issues with the front diff? I'm excited about the prospect of this project but would rather skip it if the effort ends up in vain.
 
I have been curious about this very thing myself lately. Will be interested in the responses you get.
 
I haven't seen many (if any) breakages of the 9.5 ring gear that weren't likely the result of a bad gear install. Now the pinion, that's a whole different story. I've witnessed six different pinion shears. Four on buggies that don't weigh over 4k (one is not even 3k), an FJ60 and a 40 based truggy thing. Two of the six were definitely from the pinion striking a rock as the vehicle dropped on it, the others were hard bounces attempting to climb ledges and catching some hard bounces. All rigs were running 39.5 or bigger tires. The one thing I have to add though, is that all of the trucks I've seen have a shear wheel all the time. I'm talking almost every weekend spent running some pretty serious technical trails.
 
Since such a 9.5" (cruiser diff) axle for an 80 series would be custom anyhow, I'm going to go out on a limb here and suggest a 1 ton axle. EG a 609 (dana 60 knuckles with Ford 9" center). Do it once and don't worry about it any more.
 
The work required to go 9.5 on an 80 series would be substantial. If you are swapping to hellfire high steer at the same time then it might be worth it. I have a thread on here with essentially this axle.
 
Chris Wilcox said:
The work required to go 9.5 on an 80 series would be substantial. If you are swapping to hellfire high steer at the same time then it might be worth it. I have a thread on here with essentially this axle.
Click to expand...

Post the link if you don't mind.
 
Either a Diamond or Ruffstuff front housing would replace the stock housing and let you run a 80 rear pumpkin.

Everything else can remain as stock as you wish..
 
Mace said:
Either a Diamond or Ruffstuff front housing would replace the stock housing and let you run a 80 rear pumpkin.
Click to expand...

More than likely the plan, although I've seen a mocked up version of one and it looked awfully tight on the passenger side of the pumpkin, (as far as a radius arm bracket and spring perch). Almost looked like I would have to link it to make it fit. I hope I'm just imagining that.
 
If you're going to wanna run over 37's and want to keep a "yota" axle, then yes, you'll need to do this axle. Although I have friends running FJ60 axles with RCV's and they're not breaking the axle shafts anymore than snaything else. But ideally, you want the 80-series RCV's.
I made an axle like this once. But JRob's recent build is nothing short of sexy.
 
47coeman said:
Question out there, Is there such a thing as a high trunnion 9.5 Toyota E Locker, I have not herd of one but just asking. In advance TNX.
Click to expand...

No. Only Hi-PINION 9.5" R&P I know of is a Ford D60, often called a "snow-fighter" that came in very late 1970's snow plow ford trucks. I'm sure others can correct me though, as it seems there are other Dana HP's now that I think of it...

Edit: but, no, Toyota never produced a HP 9.5" dif
 
Send that back Akarilo. This issue with yours, as you know already, is not the fault of the actual gear install....or the Nitro brand. It has everything to do why the 8 long case bolts continue to loosen up. That will ruin the strongest install in no time. I suspect nobody on the thread has ever heard of such a freakish thing..... all the case bolts loosening up for no apparent reason. And, if they have, please speak up. Right now, our best guesses might be a case that no longer has a flat surface for effective clamping action.....or the 8 bolts were severely over-tightened in the past and they are now in the stretching mode and continue to elongate even at the recommended 35~40 ft/lb.

Akarilo- I can locate 8 good V6 case bolts. But I seem to remember that they might be a tad longer than the e-locker case bolts.....just measured a V6 case bolt and the best measurement I can get is 2.905" from the clamping surface to end of bolt with standard dial calipers.

Be cool if you could find a busted e-locker that still has a good case...and good bolts. But I'm not so sure they are easily found.
Ken
 
gearinstalls.com said:
Send that back Akarilo. This issue with yours, as you know already, is not the fault of the actual gear install....or the Nitro brand. It has everything to do why the 8 long case bolts continue to loosen up. That will ruin the strongest install in no time. I suspect nobody on the thread has ever heard of such a freakish thing..... all the case bolts loosening up for no apparent reason. And, if they have, please speak up. Right now, our best guesses might be a case that no longer has a flat surface for effective clamping action.....or the 8 bolts were severely over-tightened in the past and they are now in the stretching mode and continue to elongate even at the recommended 35~40 ft/lb.

Akarilo- I can locate 8 good V6 case bolts. But I seem to remember that they might be a tad longer than the e-locker case bolts.....just measured a V6 case bolt and the best measurement I can get is 2.905" from the clamping surface to end of bolt with standard dial calipers.

Be cool if you could find a busted e-locker that still has a good case...and good bolts. But I'm not so sure they are easily found.
Ken
Click to expand...


Here's the link I did last year on your Hi-pinion 8" eleocker
Toyota gear install


Here's the 2 related pictures where I noticed the bolts were loose and I just figured at the time that the previous installer must have forgot to tighten them.......
bolt1_zpsdhpeop6s.jpg~original




bolt2_zpslqb9i414.jpg~original
 
OK....I'm doing an elocker install as I type so I will measure the length of one of the good bolts now....I measure just at 2.501"
Riley----If you measure your bolts and, if they are stretched, I would expect you should see 10 or 20 thou over that number.
IMG_7669_zpsl7fw87xb.jpg~original
 
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Land Speeder said:
I'm sure others can correct me though...
Click to expand...

Nissan Patrols have 9.5" HP front third and it's a popular conversion in Oz, in both late 70s and 80s.

Only know a couple of guys that have had available, @joekatana the last full front 9.5" HP axle I saw in the U.S.

I'd bet more could be sourced, if someone wanted to build up the front......but if you gotta ask....
 
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