Right Front Shock Replacement

[e21pilot]

I noticed oil dripping out of one of the front shocks on my 1980 FJ40 that last time I did an oil change and finally am getting around to installing a new set of shocks.

I notice the top nut is missing on the right front shock mount and wonder with the thread pitch is so I can source another nut from the hardware store.

Also, the top of the right front shock has little room for replacement because of the battery tray on that side. Is there a trick to replacing it?

 

[Downey]

Thread pitch and size will depend upon what brand name of shock you are using. After you manage to get the top nut on/or off the shock that is under the battery tray, then merely pull the shock out through the bottom

 

[Brownd3max]

I noticed oil dripping out of one of the front shocks on my 1980 FJ40 that last time I did an oil change and finally am getting around to installing a new set of shocks.

I notice the top nut is missing on the right front shock mount and wonder with the thread pitch is so I can source another nut from the hardware store.

Also, the top of the right front shock has little room for replacement because of the battery tray on that side. Is there a trick to replacing it?

I'd just take the top LEFT nut off and run down to Ace H/W. They have a thread pitch gauge & good selection...

 

[bikersmurf]

Or, take the bigger nut off the other side, tap it out, and bring the stud to the hardware store.

 

[73FJ40]

If your shock tower looks like this, and if your 1980 is the same as my 1973, the nut thread is M12x1.25. (fixed a typo; had been M14

I have a castle nut because my shock stud is drilled for a cotter pin.

 

[73FJ40]

It appears that after 1977, they did away with the cotter pin and castle nut, and went to a wave washer and nut. the nut is part no. 94130-61200, list price $1.38; wave washer, 94531-01200, $0.98 list.

 

[lcwizard]

If you have an old tie rod end around...they use the same castle nut. Most of the "Ace hardware" 12mm castle nuts are too tall. Toyota's
hardware was a bit shorter than typical domestic offerings.

 

[e21pilot]

Great responses guys, this looks exactly like the setup I have for my 1980. Now that I've started removing the old shocks I notice several missing washers and some replacement nuts as well. I'm going to order the replacements from the part numbers above so everything is in order.

Many thanks to all!

 

[lcwizard]

It appears that after 1977, they did away with the cotter pin and castle nut, and went to a wave washer and nut. the nut is part no. 94130-61200, list price $1.38; wave washer, 94531-01200, $0.98 list.

@73FJ40
Does Toyota actually sell a wave washer in that position or is it really a shock bushing washer but Toyota calls it a wave washer?

shock bushing washer ........................... wave washer

 

[73FJ40]

@lcwizard , I only posted what the EPC and the parts fiche indicate. The 'shock bushing washer' in your post is called a 'retainer' in the EPC, two different ID's (and part numbers) for inner and out.

When you call up part no.. 94531-01200, the EPC calls it a wave washer.

Go figure...

 

[lcwizard]

@73FJ40 40
They say English is one of the hardest languages. With all the industrial jargon it only gets worse. I suppose if you ask a housewife what a wave washer is, she's probably got a picture in her mind of a Maytag that cleans with waves of water and detergent.
I wouldn't be surprised to hear that the surfing community has their own version of a wave washer. There was a time that a "hard drive" referred
to that highway trip across west central Texas in the summer with your 40 stuck in low range

 

[73FJ40]

@lcwizard

Well, I ordered wave washers from Toyota for my parking brake rebuild (they go on the lever pins, under the "C" washers) and they were exactly as illustrated in your picture.

It seems that Toyota uses wave washers to take up slack in the joint? The parking brake pins would have some play without the wave washer, and I don't think you can tighten up the shock nut too much without messing up the cushion...

 

[lcwizard]

That's the purpose of wave washers. They are used to take of slack in situations where clearances aren't super precise. The wave washers
will provide tension that reduces rattling. They can actually be order with specific preloads and heights

 

[NellieFJ40]

This is certainly a timely discussion for me as im in the middle of replacing my suspension.

The discussion above, if I've interpreted correctly, means that i want springbushing washers not wave washers, correct?

If so, are the part numbers do i need to order 48510 b,c,d, and e?

Thanks!

 

[73FJ40]

@NellieFJ40

What year FJ40? early - Oct 1977, you would need b,c, d, e, two castle nuts and two cotter pins for each shock. Also the four cushions, unless you are getting them with new shocks.

After Oct 1977, b,c,d,e, two wave washers and two nuts and the cushions for each shock.

If you buy OEM shocks, some of this stuff may come with the shocks.

So, to answer your question about parts, what month/year (or, are your upper pins on the front shock towers drilled for cotter pins?) and what exactly are you replacing?

 

[NellieFJ40]

Sorry @73FJ40 for not including all the pertinent info. Thanks for following up. I've got a September 76 production date, 77 model year. I'm in the process of replacing the entire suspension with an old man emu suspension. the cushions came with the new shocks I do believe. I have all the original b,c,d,e parts, I just thought I'd replace them with new.

I understand the castle nuts are no longer available from Toyota? I'm hoping to find suitable replacements.

Thanks for your help!

 

[73FJ40]

Try these numbers:

90948-03003 WASHER, SHOCK ABSORB (B, D)
90948-03004 WASHER, SHOCK ABSORB (C, E)

94146-41200 NUT
95381-03025 PIN, COTTER

You will need two of each PER SHOCK.

I would buy one cotter pin to confirm size, and find stainless steel alternatives.

With typical 25% discounts, two of each would sell (before shipping and tax) for about $10 a set.

 

[NellieFJ40]

Thanks SO much!

You might be able to help me out one more time also. Do you know the torque values on the castle nuts and large top nut? I've looked at the FAQ but am not sure what's what.

 

[73FJ40]

B and D are identical (-03003) and C and E are identical (-03004). Toyota parts convention is to call out each as a different designation, just in case there is a difference side-to-side or front-to-back.

By the way, the parts are the same for the rear axle.

If, the castle nut number is NLA, let me know.

 

[NellieFJ40]

Will do. Thanks again for your help!