Solid Axle Swap

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jonheld

jonheld

10 Year 15 Year
Joined
Dec 8, 2006
Threads
456
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13,154
Location
New Jersey
Website
www.sdsysdesign.com
I think I'm starting down a dark and expensive path, but I need to test the waters here. I am seriously considering a 99-02 100 Series as a candidate for my next truck. However I would need to hack out the IFS and glue an 80 Series front in there to accomplish what I intend.

Basically I like the idea of a truck that was built in the current century with all the safety features and that delicious V8. But I love to rock crawl in my 80 so a solid front is a must have for me. The size and shape are basically the same as an 80, so I should be able to keep it intact for the most part, but I want to run 36" Swampers in the woods.

I have been searching this forum and see only bits and pieces of information regarding an SAS. Who has done it and are you happy?
 
jonheld said:
I think I'm starting down a dark and expensive path, but I need to test the waters here. I am seriously considering a 99-02 100 Series as a candidate for my next truck. However I would need to hack out the IFS and glue an 80 Series front in there to accomplish what I intend.

Basically I like the idea of a truck that was built in the current century with all the safety features and that delicious V8. But I love to rock crawl in my 80 so a solid front is a must have for me. The size and shape are basically the same as an 80, so I should be able to keep it intact for the most part, but I want to run 36" Swampers in the woods.

I have been searching this forum and see only bits and pieces of information regarding an SAS. Who has done it and are you happy?
Click to expand...


Just know your track width on an SAS 100 will be wider than an 80... and to the best of my knowledge an 80 front axle assembly isn't wide enough for the 100 frame rails...
 
Last edited by a moderator:
jonheld said:
Well then what are folks using for the front?
Click to expand...

The answers are in the links friend.

".....front axle utilizing a True Hi9 center section with a mix of FZJ80 and FZJ105 Land Cruiser parts to retain field servicability.......
 
I started typing a long thread with similar questions recently and accidentally deleted it before posting it... I never took time to start another thread but I have also been looking into this... I was thinking of beginning to collect everything needed to do the SAS and attempting to do most of the work. I have looked at custom built hybrid solid front axle options from TrueHi9, Diamond, Currie, maybe start with a housing from RuffStuffSpecialties or someone similar... I would be nice to put together a working list of parts and items needed to do this conversion... I can't afford to ship my truck off to Slee for a complete turnkey SAS but I would consider paying for labor / install assistance to get everything bolted up correctly after I have all the parts needed... I was thinking I could just start collecting everything over time and it wouldn't hurt the wallet as much... I would also like to be able to run up to a 39 or 40" tire...
 
spressomon said:
Just know your track width on an SAS 100 will be wider than an 80... and to the best of my knowledge an 80 front axle assembly isn't wide enough for the 100 frame rails...
Click to expand...

Yes you right, the 100 series axle is 5" wider than the 80 axel.

But the distance between the wheels are almost the same,
80 rim to rim = 55" / 100 rim to rim = 54". the rim backspace make the difference, but i don't have any idea why this SAS it is not popular!
 
it is not the popular for 1 reason



$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$
 
So at this point it looks like a $20k project from where I sit. figure 10-12 for a descent truck and the rest in Fab and parts and bolt ons. Probably not going to happen until my kids are done with school.
For significantly less than that I could do a body swap and a Toyota turbo diesel.

I dont know. My head hurts.
 
jonheld said:
So at this point it looks like a $20k project from where I sit. figure 10-12 for a descent truck and the rest in Fab and parts and bolt ons. Probably not going to happen until my kids are done with school.
For significantly less than that I could do a body swap and a Toyota turbo diesel.

I dont know. My head hurts.
Click to expand...

I would have thought it was $15k - $20k for parts/labor in ADDITION to having a 100-series to start with.

Or perhaps I misunderstood, and you are saying that with more of a DIY approach it could be done for $8k - $10k in parts/labor + a 100-series?
 
I would rather see a long travel IFS system for these trucks. Great ground clearance with more composed flex. Big coilovers and long arms, that would be my setup if I had the choice.
 
jonheld said:
I think I'm starting down a dark and expensive path, but I need to test the waters here. I am seriously considering a 99-02 100 Series as a candidate for my next truck. However I would need to hack out the IFS and glue an 80 Series front in there to accomplish what I intend.
Click to expand...

:idea: why don't you keep the 80 for heavy wheeling?

Buy a 100 for the other 95%? I would like to have another 80 at some point.:)
 
bluecruiser said:
I would rather see a long travel IFS system for these trucks. Great ground clearance with more composed flex. Big coilovers and long arms, .
Click to expand...

how much will cost that .. vs SAS ..
 
Tapage said:
how much will cost that .. vs SAS ..
Click to expand...

Never looked into it serious enough to gather costs. I'm guessing around the cost for SAS. Would need custom CV's, spindles, upper and lower arms. Not sure about steering changes and upgrades. I'm thinking the stock rack and pinion would not cut it. One offs will always be expensive.
 
jdlsantos said:
Yes you right, the 100 series axle is 5" wider than the 80 axel.

But the distance between the wheels are almost the same,
80 rim to rim = 55" / 100 rim to rim = 54". the rim backspace make the difference, but i don't have any idea why this SAS it is not popular!
Click to expand...

On the Extreme Landcruiser site they were advertising a sas kit you can order and they have the option of an 80 series front axle or a custom built axle. The one they did with the 80 front axle looked fine
 
I believe Slee said that the 80 series axle is not strong enough for the weight and power of the 100 series, hence the need for the custom axle.

I do like the idea of the long travel IFS, however the 100 series is already wide enough to begin with. I think the Tacoma and mini truck kits are 3" wider per side. That would make the 100 ridiculous to drive on most trails. I think a mild 1-2" wider per side will be more reasonable, but not sure if the cost for such a kit will be really worth it?
 
Why stick with toyota parts? Why not just swap a dana 60 front and 14 bolt rear and be done? Any good 4wd shop should be able to three link the front and retain the stock rear suspension setup or swap to a triangulated four link rear.
 
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