Rear shackles removal

[PaulGrant]

Hi there,

I am attempting to replace my PZJ70 1990 SWB cruiser rear shackles and just cannot remove the 2 rear shackles as they are being blocked by the fuel tank.

See attached photos.

 

[roscoFJ73]

I dont recall having that problem. Has it been put on the wrong way or was the tank put on different? Looks like an angle grinder job

 

[Blomdala]

1. It seems like it could have been put on backwards by previous owner.
2. As smart as Toyota engineers are, this would not be the only vehicle that requires something ridiculous to be removed to remove something simple. (Check out Tacoma upper control arm bolt removal)

 

[NM Frontier]

When I did the OME on my BJ74 I just cut them off, pretty sure that is a common way to deal with it if you are replacing the shackles any way.

 

[roscoFJ73]

I think the ones with rubber are harder. Mine with polyurethane bushes fell out. But they should come out with no cutting so you can replace components off road without taking a reciprocating saw.

 

[roscoFJ73]

Those 2 bolts going into the chassis dont look too OEM

 

[roscoFJ73]

Looks a bit different and shackle bolts go the other way

 

[PaulGrant]

When I did the OME on my BJ74 I just cut them off, pretty sure that is a common way to deal with it if you are replacing the shackles any way.

Sure, cutting them off is easy, but I cannot 'cut them in'

 

[PaulGrant]

That

Looks a bit different and shackle bolts go the other way

View attachment 2217145

That explains it, previous owner put them in the wrong way, but HOW???
If they cannot come out then surely they cannot go in!

 

[PaulGrant]

Those 2 bolts going into the chassis dont look too OEM

They are part of the towbar.

 

[Blomdala]

That

That explains it, previous owner put them in the wrong way, but HOW???
If they cannot come out then surely they cannot go in!

Maybe the bushings were softer when they were installing. Or they happened to have the tank out.

 

[fjc-man]

Cut them off with a carbide tipped reciprocating saw blade. Diablo brand, cuts like butter. Then install the new ones the right way.

 

[PaulGrant]

Maybe the bushings were softer when they were installing. Or they happened to have the tank out.

Yeah, that is what I was thinking. I will have to cut them out and then loosen the exhaust and then force it in. Is it a big job to drop the tank?

 

[PaulGrant]

Cut them off with a carbide tipped reciprocating saw blade. Diablo brand, cuts like butter. Then install the new ones the right way.

To do this I must either drop the tank or loosen the exhaust.

 

[fjc-man]

You do know what a Milwaukee sawsall is...right?

 

[Blomdala]

Yeah, that is what I was thinking. I will have to cut them out and then loosen the exhaust and then force it in. Is it a big job to drop the tank?

If the tank is full, yes HA, if not, then not terrible, just be careful disconnecting fuel lines. You might have enough to just losses the straps with a jack supporting it, to move it to the side enough to get the shackle out.

 

[roscoFJ73]

I would rather cut the shackle bolts than remove a tank thats been in place for 30 years.

 

[roscoFJ73]

That

That explains it, previous owner put them in the wrong way, but HOW???
If they cannot come out then surely they cannot go in!

Maybe they can be wiggled in/out at an angle with only one half of the shackle in place. Is the exhaust in the way also?

 

[Hugh Heifer]

I had the exact same issue on my BJ73. I am pretty certain this was a factory install.
I cut them off with a reciprocating saw and then replaced them with the shackles in the Iron Man lift kit. The replacement shackles had removable pins unlike the OEM ones. I did not feel bad about cutting the oem ones as the pins were pretty beat, corroded and worn.

 

[divemedic]

Yes they’re backwards, no you don’t have to cut them out.

- pull the bolts off
- pull off the plate
- remove the spring and let it hang clear from the area
- pull the outboard bushing from the chassis mount

all the should remain at this point is the inboard bushing and shackle with pins.

- use a deep-well 22mm (iirc) socket to clear the upper pin and hammer the shackle out. There should be enough clearance to wiggle it out.

you may need to use a mapp touch to burn out the old bushing depending on how much corrosion is present.