Made a few tool friends this weekend working on the 200 to install Old Man Emu lift kit:
1) Toyota factory jack (surprisingly put the floor jack to shame in usefulness for getting the front of the truck up on jack stands- floor jack was great for manipulating suspension though)
2) Penetrating oil made it a lot easier to get some of the suspension bolts out
3) BFH (picked up a 4 lb sledge and made short work of the tie rod bolts)
4) Pry bar saved my butt a couple times with the sway bar linkage bolts connecting the sway bar to the lower suspension arms
5) Punches were key for the single bolt holding the bottom of each strut
Unfortunately, a couple challenges of the install means I'll have to make a second attempt next week.
Here were the show stoppers:
1) LCAs have seized cam bolts. I've got a brushless sawzall and medium and thick metal blades and new OEM LCAs and hardware ready to go in. But not looking forward to cutting the old bolts and sleeves out.
Question to the group: Anyone have any tips for cutting seized cam bolts out?
2) I couldn't for the life of me pry out the worn Old Man Emu shocks by loosening up the upper ball joints, removing the steering rod ends, and removing the bolts connecting the sway bar to the lower suspension arms... I left the nuts retaining the upper ball joints on, leaving about half the nut on the end of the thread, after giving the the top of the steering knuckles a good thwab with the BFH to allow them to drop down onto the nut. To prevent the risk of the CVs falling apart, I did not completely remove the upper ball joints. But using a big flat head screw driver and a pry bar, I could not get the bottom of the old shock to slip out after removing the single bolt and removing the top 4 bolts.
Question to the group: How can I pry and leverage the old worn Old Man Emu shocks out of the lower suspension arms? Do I need to drop the LCA instead of just loosening the upper ball joint?
Any other good natured tips appreciated!
Thanks y'all- I always appreciate the group's expertise.
Here are the instructions I was using:
Step-by-step installation of a Tough Dog suspension kit in a Toyota Land Cruiser 200, including springs, struts & shocks. Including how to fix a KDSS lean.
www.project200.com.au