Complete success.
Okay
so we are at the end of this PTO winch shaft re-manufacture/replacement build.
First, I want to thank all of you for your inputs and pictures that I may of requested for information on the PTO and shaft to help me build this to as in close proximity to stock functioning as possible. I sense this will be a big help to others that may have questions on PTO shaft and parts. I openly would do this again if the parts such as the winch yokes and PTO yokes were readily available like they were 30 or so years ago, but now they are almost sparse to being extinct and they are key fundamentals in making it all work.
I only started off with the winch and a winch yoke and am lucky I had that. For you folks that have all the parts, then this would be a breeze for you to reconstruct, but for the folks that want a PTO winch and are starting from scratch before you buy that winch for that crazy price, make sure you have every little part with that or be ready to do a lot of leg work in looking for the parts.
As for the price, what the folks are asking on some of these PTO winches and assemblies, I am a little in the middle on how I feel. The winch I bought was my first PTO type after owning many electric winches that are absolutely fine and did the job. I like the direct power of the PTO and torque, but it is limited in its max weight pull in what it can pull compared to an 8,000lb or 12,000lb electric winch. Electrical winches work just as well than a PTO type other than the once and awhile power tribulations, and battery thermal runaways but what doesn’t have a problem once and a while. When someone is asking $1,300 -$2,000 for a PTO set up that has no replacement parts from the dealer and other than what you search the world for or have a small stash of parts, you better hope it will last. I would think that they would sell for about $500 just to be rid of it for the said reason. But as for me I wanted to try one and see what it was all about and add a bit more of the Toyota originality also. So what ever the reason I would say if it is not complete in parts, be prepared.
As for the parts used on the shaft, it was a lot of leg work to find the items that would work together and keep that Toyota look using the factory frame mount holes along the inside of the frame. As you can see in the pictures the bearing mounts are just angle iron and the bearing purchased were ideal for this job, and they work well with the loads, and can be replace straightforward.
Not knowing if Toyota used a hollow pipe or solid round steel for the shafts and then welded a spine to the end, but due to the lack of shafts ends I determined it would be best with what I had in mind to go with solid 1” steel shaft.
The solid shafts seemed to be well-matched with a variety of manufactures of yoke ends that are used in the market today so 5’ of 1” shaft was bought at my local steel supply.
The 1” shaft was my first item bought, then I looked at the year Toyota I have and them looked at the original PTO parts semantics noting it had two hangar bearings and two yoke assemblies.
I have the factory holes in the frame for this 1982 year shaft run, and all were usable to mount this entire shaft. After finding a Toyota four bolt PTO yoke assembly for the companion yoke I was ready (did not have to build one from after market parts).
When completed, I use an application of clear spray metal protection on the complete length of the shaft and any part of steel that is not painted. This leaves a waxy hard solid protective film on the surface and will last for long periods of time.
This is mainly for if I have to remove the shaft or bearing, all I need to do is steel wool the ends so the collars will side off much easer and is much better that removing paints due to the close tolerances between the shaft and collars with the build up of the paint. I use the same spray protection inside the PTO spine area and the winch spine area with a mix of grease, and also on both spines.
THE TEST
Started up the truck with the winch disengaged, transfer in neutral, Trans in reverse gear and slowly let the clutch out. At first I thought is was not operating, I could barely hear it spin, but I did not hear any banging or worse so I got out and took s look, she was spinning just as it should and I could now hear it much better from underneath. I have ½ “of sound deadener pad under my mats and trans hump so this is why I could not hear the shaft turning.
All looked fine and no wobble at my shaft spine welds. Ran it for about five minutes, while running I pulled out around all 120” feet (have 120’ on drum marked with yellow paint every twenty feet) of cable and attached it to my Toyota pick up truck for the pull test.
With both vehicles in line of each other I engaged the winch for the test. As the line slack was taken up and that first tighten of the wire rope I felt a big relief as the winch without any hesitation started to pull my pick up towards me. My wife who was in the 45s drivers seat controlling the master shut down just incase while I was outside (is a two person job if possible). After the truck pull was completed my wife said now can we pull that tree stump out now? So being that the tree stump also was in line with the truck I removed the cable and notched the stump for the chain that is around 7-8 inches wide stump and processed the pull. The stump was out of the ground in less than 35 seconds and the roots were deep. Not one snap, crackle, or pop. The PTO winch and shaft is a complete success. A group of pilots plan on doing some tree falling/wood cutting for our low income local’s folks that use wood to heat their homes in the winter months, so this will be one of the winches first big jobs soon, pulling logs.
I hope this post being a bit long but with all the information give from all of you will be a help to a few of you that are planning a replacement build of your shaft and help save you some leg work in building your own shaft assembly, be it a two hangar bearing shaft, single bearing, hope it helps. Thanks again to you guys for the help.
PARTS FOUND FOR THE CREATION OF THE SHAFT
Item A:
Two ends of transmission input 10 spine shafts. Both were cut and welded onto the 1” solid shaft using a homemade jig. Both shaft and spine are the same in diameter so was a perfect match. Use a circler power sander with a 220 grit or more, and lightly sand the spines one at a time very
lightly. The center of the input spines are high and that is the only area to be concerned about. Being the trans input spines are a hair bit taller that the original PTO shaft spine, and believe me
ONLY take a hair off even it you have to go back ten to twenty times to check the fit to your yoke end. I did two to three light passes on each spine with my grinder /sander, and achieved what I call a nice fit, slides in and out but not to loose but not tight, snug. So hang onto some of those old transmission parts, they come in handy.
Item B:
Four end yokes with 1” center with ¼ “shaft keys shaft pin. Two u-joints, these were referred to as PTO yokes and are in 1000 series type. They match the size of the Toyota yokes reasonably well but the Toyota yokes are still a bit smaller that these.
The yokes are from Neapco Corporation, part number
10-0493; two are required per set with one u-joint.
I used
GMB u-joint, Part number
210-017 for one and
Spicer 5-170X for the other. Both were found on
EBay for a good price. You can do a search on the net for the yokes as they are everywhere, and cheap.
The four shaft keys way will be cut for the ¼ keys when all the fitting it completed. Also the shaft will be drilled for the set screw so I can have a bit of security at both sides of the collar along with some tread lock liquid.
Item C:
Two hangar bearing with 1” centers, and with 1 grease nipple each and two collar set screws per bearing. They are the
VXB UCHA205-16 series and can be found any were for a good price. I bought mine at Sears on line for a round $11 each. Easy to replace and they fit in the tight area. I chose these so I could adjust the bearing with ease at the shaft end were it goes into the frame hole to the winch yoke. “Worked nice” I plan on building an elements shield to put around them to help keep out the water and mud as they are not sealed like the Toyota hangar bearing but with some effort will be fine, and can grease them from the top side as needed from a cutout slot I plan on making to both mounts tops.
They take 1” bolts so be ready and get a shorter length bolt if feasible or have some way to cut them down so you do not have to use washers for spacers. The bearing tread shaft is only around 1” deep. Take the bearing with you when shopping for a bolt.
I used four washers on the top of the bearing body between the mount and bearing on the front to shim it to the correct angle (height) to fit the shaft frame opening flawlessly on all sides.
Item D:
4”x4”x1/4” angle iron from scrap yard, will hole a house up so was the easiest way to go and works nice. When setting up your compete shaft assembly and when you find the correct height for the first bearing coming from the PTO end, I used a welding clamps to hold in position while I used a strong bent wire to etch though the back of the screw holes from the inside of the frame, so when I removed the plate it shows the etching of the wire and a place to drill. I used paint on the front around the mount holes and clamped the plate back into its location and let it dry over night and then when removed it had the outlines of the four mount holes and a place to drill. The front plate it you go this way needs to be trimmed on the top so it does not obstruct with the crank belt or any other forward engine part. As said in “C”, I plan on cutting a slot out on the top side of the mount so when mounted I can lube the bearing with little effort.
Drill the 1” bolt mount holes for bearings. I used a 1” drill press hole cutter that worked perfectly.
Item E:
1” steel round shaft 5’ long.
Item F:
Two bolts – just the 1” bolt as describe above.
Now to go fly.
Cheers

