Build Stretched 1-Ton FJ40

[Mike Shull]

This Land Cruiser has been in the family since 1978 and it has gone through multiple builds already. It currently sits on 35s, SOA, power steering, 383, SM 465, and a rear locker. The plan is to stretch it by 14”, replace the engine with a 6.2L LS, then install an NV 4500, Atlas 4, and 1 tons with ARB’s, 5:13 gears, sitting on 40s.

Update on 10/2025: Here is a clip of the build from 2021 - 2025. There is still more to do though it is nice to be able to take my time and drive it between projects again.



Part 1: Stretched Chassis & Custom Suspension


Part 2: Drivetrain

186:1 Crawl Ratio That Hits 75 MPH--FJ40 Drivetrain Breakdown

My 1978 Toyota Land Cruiser FJ40 runs a 186:1 crawl ratio for the rocks, yet it still cruises at 75 miles per hour at 2500 RPM on the highway. This video bre...

youtu.be

 

[Mike Shull]

I found a set of axles that were partially built. I went with the drive terrain from a 1987 K5 military Blazer that had a Dana 60 front and a Corporate 14 bolt rear. I swapped out the rear single wheel hubs for dual wheel hubs to bring my wheel mounting surface (WMS) to 63”. Later I will add disk brakes to the rear.

Next I cut down the left side of the Dana 60 to match the rear 63” WMS and I had a custom 35 spline chrommoly shaft built from Currie Enterprise. The right side already had a chrome moly axle. Minus a seized wheel bearing, these axles look to be in great shape!

 

[matzell]

Here is a tube I cut the C off and pressed out.

 

[Mike Shull]

@matzell, were your tubes painted under the Cs?

 

[matzell]

I am not sure but i would think not

 

[Mike Shull]

Does anyone know if these are true beadlocks? Abrams Truck Rims by Black Rhino - https://www.blackrhinowheels.com/off-road-wheels-rims-abrams.php

 

[mr jits]

Does anyone know if these are true beadlocks? Abrams Truck Rims by Black Rhino - https://www.blackrhinowheels.com/off-road-wheels-rims-abrams.php

I'm pretty sure they're not, and it looks like the "rock ring" is just a machined lip with bolts.

 

[Mike Shull]

I think that you are right, @mr jits. This must be their true beadlock version:

Garrison Beadlock Truck Rims by Black Rhino

The Garrison Beadlock truck wheels by Black Rhino. Explore our selection of aftermarket truck rims designed to precisely fit your vehicle.

www.blackrhinowheels.com

I’m not sure that I like this design. It’s a good thing that I have time to decide. Nice Cruiser, BTW.

 

[mr jits]

I like the look of that wheel. Personally, I'd go the internal beadlock route with a wheel that utilizes replaceable rock rings if I were looking at something like that again. That's totally a personal preference though.
I like where you're going with your rig. Subscribed.

 

[Mike Shull]

Thanks, @mr jits. I’ll have to look at internal beadlocks. I would like to drive this on the highway for long distances. Given that, would you still prefer the internal beadlocks? Can I run balance beads with this setup?

 

[mr jits]

Thanks, @mr jits. I’ll have to look at internal beadlocks. I would like to drive this on the highway for long distances. Given that, would you still prefer the internal beadlocks? Can I run balance beads with this setup?

You can, and from what others have said, they work well with the balance beads (I used airsoft pellets with my beadlocks and they worked great).

 

[Mike Shull]

Excellent feedback. I like this option and I will most likely pursue it. Thanks for the tips.

 

[Mike Shull]

The fun begins this morning with the reassembly of the front Dana 60.

Does anyone know what the number means that is stamped into the top of the inner Cs? East Coast Gear Supply did not know. I am guessing that they are the production number. @matzell ?

 

[Mike Shull]

No worries on the above question. I installed them anyway. My welding skills are a bit rusty but it will be sufficient.

Reassembly day one:

 

[Mike Shull]

The right side is done.

 

[matzell]

While you have the welder out, weld the tubes to the center sections so it does not spin, YES it happens.

 

[Mike Shull]

Thanks for the tip, @matzell. I will do that this afternoon.

Do you have any idea where these c clips go. I thought that they were for the end of the axle shafts but that clip is pictured on top. I have 4 of them and I don’t remember taking them out.

 

[matzell]

Thanks for the tip, @matzell. I will do that this afternoon.

Do you have any idea where these c clips go. I thought that they were for the end of the axle shafts but that clip is pictured on top. I have 4 of them and I don’t remember taking them out.

View attachment 2689024

The 3 look like UJoint clips. The single looks like the one for the end of the axle stub shaft.

 

[mr jits]

Thanks for the tip, @matzell. I will do that this afternoon.

Do you have any idea where these c clips go. I thought that they were for the end of the axle shafts but that clip is pictured on top. I have 4 of them and I don’t remember taking them out.

View attachment 2689024

When I picked up my Yukon's I had leftover clips. Drove me nuts for a couple of hours before I called in to ECGS and they let me know extras are typically provided.
I AM NOT stating this is the case here.

 

[Mike Shull]

The 3 look like UJoint clips. The single looks like the one for the end of the axle stub shaft.

I forgot that I took apart the left u-joint in preparation for the shorter shaft. Thanks for the kind reminder. Those are definitely u-joint c clips.