The one ton swap thread

[cody c]

“High Angle driveline can hook you up with the proper Toyota flanges for most axles.”



Ya, I’m aware, but they cost at $109 for the D60, and $200 for the rear, I would be at like $450 or so CAD shipped. Gotta eat some costa somewhere and I occasionally have access to a lathe so it’s moved from something I buy to something I try and make, but I did consider it.


Edit:
A buddy (Corey) has time for welding/building so he took the 14 bolt, we got measurements for brackets and such, gonna get it assembled.

Got the front rotors milled, and a pic of the ford TRE, vs the 80 end

Also, found out my transmission is fine, rear diff however, not so much. Front wheel drive it is!

 

[cody c]

Not much to report, the 14 bolt is getting some work done but no pictures yet, picked up some round over router bits, 1/4” round over seems to be the one for rounding aluminum beadlock outer rings. I got a set of a few sizes and it was the best for 3/8” thickness aluminum.

Did get the front axle outers in place for welding, and a piece of pipefor an inner sleeve, but the inner pipe is like 1mm too large (or rather sleeve is 1mm too small) so it looks like I’ll probably get another piece of pipe and have it turned down.

Final picture, I have airbags on this thing, for the most part they work well and allow me to drop height enough to get it in the garage, but the firestone rolling lobe bags leak and are not the best design for my application. I’m switching to these Boss 2503 airbags, I have this one and another in the back after swapping out a firestone, but the end plates are rusty AF, so I grabbed some more aluminum plate to replace the steel ends and ordered two more bags to swap out the leaky front bags when I get to that part of the swap.

 

[Broski]

Not much to report, the 14 bolt is getting some work done but no pictures yet, picked up some round over router bits, 1/4” round over seems to be the one for rounding aluminum beadlock outer rings. I got a set of a few sizes and it was the best for 3/8” thickness aluminum.

Did get the front axle outers in place for welding, and a piece of pipefor an inner sleeve, but the inner pipe is like 1mm too large (or rather sleeve is 1mm too small) so it looks like I’ll probably get another piece of pipe and have it turned down.

Final picture, I have airbags on this thing, for the most part they work well and allow me to drop height enough to get it in the garage, but the firestone rolling lobe bags leak and are not the best design for my application. I’m switching to these Boss 2503 airbags, I have this one and another in the back after swapping out a firestone, but the end plates are rusty AF, so I grabbed some more aluminum plate to replace the steel ends and ordered two more bags to swap out the leaky front bags when I get to that part of the swap.

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Keep the bearing lubed, I use silicon spray and Inspect the bearing often as they tend come off when routing aluminum.

 

[cody c]

Thanks for the tip. I sprayed it every minute or two with WD40 as well as the aluminum so the carbide didn’t gum up, but it is a good thing to mention.


Edit: I hit some roadblocks today. I found out the high steer arms haven’t shipped yet and I think I ordered them well before christmas (Covid at their shop apparently)

And the new hardware I ordered (M8 x 40mm stainless torx countersunk/flush head ordered a while back for the beadlock rings haven’t shipped as the vendor days they are out of stock from China, but it looks like they changed the price and don’t want to honor the price as advertised.

Aliexpress/Alibaba... tend to order from there cause I can get free shipping, whereas I looked at ordering $22 worth of bolts from the US and they want to charge $80 for shipping.

 

[cody c]

Some pics from the welder

 

[cody c]

I guess he’s dropping off the axle today, better get the 80 in the garage to start pulling stuff off of it.
Normally it sounds fun, but it mostly looks like more work to be done.

Edit, started pulling the nose come on the full time t-case so as to redrill and relocate studs to match the DC 4Runner shaft for the front, and then Corey dropped by with the rear axle so I threw some primer on it

Also, the fella that built the brackets with exception to the artec truss says he’s happy to make more if anyone is interested I can PM his contact info. He’s in Calgary and his prices were reasonable.

The bag mount is for the Boss 2503 bags, but he can build to your spec for coils.

 

[cody c]

Not a lot of progress on my end lately, I did get it in the shop this weekend, dropped driveshafts, pulled the 60 case, started cleaning up the full time case and I’ll pressure wash the 60 series case to sell with the advanced adapter kit later after I pull the chopped output shaft.

It makes sense to pull and swap the t-case and put in the output shaft while the stock axle is still in. Don’t want to get under it too much for the transmission if the axle isn’t completed with tires on in the back, and I still want to powder coat the wheels first before assembling.

I grabbed a 4runner rear shaft for the DC end, cleaned it up the other day.

Hoping to have the trans reassembled and back in within a week (for the HF1A) and back to axle swap work.

 

[cody c]

Edit: apparently there is two packages, one sent UPS the other USPS

I was bummed that it seemed like half the package was missing

 

[Wheelingnoob]

Well... big let down. Not a game stopper but, this adapter kit I ordered from Adventure Vehicles NW finally got here, I had it delivered to a friends place in Philadelphia and then he forwarded it here with a bunch of personal belongings as he’s moving here, it got held up in customs forever.

It showed up without the output shaft. I ordered beginning of December.

We will see how Jonesys handles it. I emailed them because they don’t show a phone number anywhere.

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That's no good! I thought they were totally out of the picture now.

 

[lt1fire]

Following this as I have a super duty D60 and matching locked sterling 10.5 in the garage from a different project.

If I do decide to put my 4bt in the cruiser at some point I may want the extra beef.

Are you going to do the D60 birf style joints?

 

[cody c]

That's no good! I thought they were totally out of the picture now.

I edited my post, apparently they are being shipped. Gotta figure out the details to get it reroutes here.


I like the D60 CV birf style shafts, but they aren’t cheap.

Edit:
Looks like the output shaft shipped, is shown as delivered but never showed up. Not sure how it will be resolved, but it will need to be figured out sooner than later.

Double edit: the shaft was shipped separately via USPS and never showed up, there is a tracking number and it says delivered. Andy my bud was at the house that day with his grandson (daughter having a second kid so he was back down for a visit) and around the house all day but no package. I’ll either need Adventure Vehicles NW to replace it, or if they’re unwilling I’ll ask to sell just that component at cost.

 

[cody c]

Not much to post, trans is out awaiting some parts for rebuild, pulled the rear axle finally today, it seems everything possible got in the way in January, gonna start hacking up and lengthening the lower links tomorrow, and cleaning under the truck a bit, maybe wire wheel and paint the frame in some spots.

Edit: some progress on links

Gonna finish the lowers tonight or tomorrow and press bushings out and new ones in and some fresh paint

 

[cody c]

Not much for updates it’s been in the -20’s here the last few days and my garage isn’t well heated.

got the rear control arm bracket chopped off, cleaned up the frame up with the flap disk and wire wheel, rust converter and rocker paint on the frame.

Was gonna get the one lower bolted up but the bracket conflicts with the end of the arm, need to cut out the black on top/bottom left and right for the arm to fit in.

Tomorrow task will be to notch the brackets and get it back under.

 

[YMT]

I gotta say, this thread has me a bit disappointed after the first post, as I was hoping to see more content about axle donors and obstacles that others overcame.

That said, @cody c , I'm really enjoying the axle porn. Keep up the progress, and hopefully it warms up for you to get some more fab and wrenching in

 

[cody c]

I gotta say, this thread has me a bit disappointed after the first post, as I was hoping to see more content about axle donors and obstacles that others overcame.

That said, @cody c , I'm really enjoying the axle porn. Keep up the progress, and hopefully it warms up for you to get some more fab and wrenching in

Ya.. no offense taken, but your right, this thread does kinda suck. The project kinda sucks too, held up on everything, been waiting since December for steering arms, still not here, airbags got sent the wrong place, waiting on a bunch of hardware, still not here, want to sand blast wheels ( the business that does it is closed for Covid, and cause it’s -28c here today) and I’m held up cause of my own procrastinating. But it is what it is, no butt hurt.

I’ll continue to post stuff to the thread, I’m trying not to bump it up too much (I edit stuff in to add things instead of posting more) but i think the topic just isn’t that interesting for majority on here, and that’s fine. I’m Content to document this for myself and anyone using the search function later down the road, I’ll be moving forward at the same speed regardless of commentary.

Edit: I think I may install some “rock lights” in the rear wheel wells today. I have some in the front and can just tie into them, and have LED lights for the rear sitting in the cabinet. It would be smarter to do that now and be able to see better what I’m working on.

 

[YMT]

Ya.. no offense taken, but your right, this thread does kinda suck. The project kinda sucks too, held up on everything, been waiting since December for steering arms, still not here, airbags got sent the wrong place, waiting on a bunch of hardware, still not here, want to sand blast wheels ( the business that does it is closed for Covid, and cause it’s -28c here today) and I’m held up cause of my own procrastinating. But it is what it is, no butt hurt.

I’ll continue to post stuff to the thread, I’m trying not to bump it up too much (I edit stuff in to add things instead of posting more) but i think the topic just isn’t that interesting for majority on here, and that’s fine. I’m Content to document this for myself and anyone using the search function later down the road, I’ll be moving forward at the same speed regardless of commentary.

Your content has been great! Very detailed and picture heavy. My disappointment is in wanting to know what others are using for tons. So, I wasn't trying to bash on you or your thread; just trying to encourage others to provide insight on their projects.

I am hoping to tackle this in the future...

 

[I Lean]

(I edit stuff in to add things instead of posting more)

Really? Now I'm gonna have to go back and re-read everything to see what I missed.

 

[cody c]

So, gonna bend some pipe tonight for the upper wishbone link.

Put some rock lights in the back to see what I’m doing better.

Got two sets of wheels, beadlock rings, calipers, some 6 shooter knuckles and a few other parts sandblasted today. Gonna try my hand at powder coating tomorrow.

Trans was dropped off for a light rebuild and output shaft swapped to go back to a full time case.

The fella burning the Dana 60 back together has the alignment bar now and is making some pucks out of aluminum to work for the newer style knuckles to align them as well. Newer style is unit bearings. The alignment bar jig has pucks for spindles on earlier style Dana 60 axles.

Fricking high steer arms finally got here and are off for machining.

Also been debating an Auburn E-locker for it, but as the locker is ordered for 4.11 gear and under or a different one for above 4.11, I’m definitely gonna wait and make sure I like 4.11’s with it.

Airbags are set for a bit less height than needed, had to order a 1.5” x 5” piece of rubber disc as a spacer so I won’t be hitting fender if it’s maxed out, or out of air in the bags.

I think the last note, ordered some synthetic line to replace the frayed steel cable on the 8274 as well as aluminum fairlead. Scope creep...

 

[leonard_nemoy]

Freaking sweet, I am loving this thread.

 

[cody c]

Got some tube bent tonight too

Will see if it fits for the upper wishbone sunday. Buddy bought a 1.25” die set for this