I knew this was eventually going to happen and here I am...IFS is toast, rear springs are beyond sacked out. Only one option to fix it. . .SAS!

Here is what I am working with:

1992 SR5 w/ a 3.4 from a '98 Taco 220km on body around 100kms on the
motor.

I purchased the 3" Trail Gear IFS Eliminator kit w/ HD front springs and 3" rear kit to match.

The axle is off an '84 FJ40.

Stock gear ratio is 4.56 on the rear, so I bought a 4.56 ring and pinion setup from Randy's Ring and Pinion for the FJ40.

All the parts are here, now it's time to get to work.

 

Broken rear leaf spring...
IFS shot.
The Axle!

 

There was a bit of a groove on both the balls, so I JB welded them and sanded them down to round...hopefully round enough!

 

Yukon 4.56 ring and pinion set.
Third all set up and waiting for me to get my A$$ into gear...

 

Off to the shop to start cutting out the IFS. Plasma cutter is down so its either grinding wheels or hopefully an oxy acetylene torch.

 

Got the IFS cut out today with an oxy/acetylene torch. I might have lost a few brain cells from the fumes, but I probably didn't need them anyways!

Gotta love the old rusty control arms sitting in a heap!

 

Spent most of today grinding. Picked up all new brake calipers and pads. Also got my knuckles back from Pete, who did an awesome job sandblasting them. They are all primed and painted ready for the axle tomorrow!
Here is the before and after grinding shots and the truck as she sits.

 

Brakes are ready, knuckles are almost done and the tubes are in.
Next up....spring hanger and hopefully the axle will be under the truck tonight!

 

Nice work!

 

Hey, Idiot you done your truck yet? What happened to 2 days?
(more pictures)

 

Here is the problem (unfortunately I forgot my camera too...)

The rotors on both sides are binding the inside of the calipers and I have no clue why.

The setup is IFS Hubs, mini truck knuckles, FJ 40 rotors ( Trail Gear Kit) and IFS V6 Calipers.

I am off to research if anyone has had this issue and if so, how they solved it. If anyone has any suggestion, I am all ears!

I will have pics tomorrow

 

Thanks SCToy! Hopefully it all comes together nicely...

89yoter...hows your first gen coming along?? hahahaha

 

So after an insane week of downhill biking and drinking beer all over BC, I finally got back to the money pit.

My rotors were binding on the inside of my calipers on each side. After some reading on pirate4x4 and here the only way to solve it was...

Caliper ears meet grinding wheel...grinding wheel, meet caliper ears.

 

So i am a bit slow (and new) to this fab stuff, so this wasn't exactly an efficient process for me. It took me the better part of 3.5 hours to get the first caliper figured out and about 30 mins to do the second one!

Here is how they sit now...not perfect but driveable and (somewhat) safe.

Hopefully this time tomorrow there will be an axle under my heap.

 

Clears by a C hair. I like it. Now hurry up and drive it.

 

So it turns out the "FJ40" axle I bought is really an FJ60 axle. I took the seller at his word and didn't measure it. My bad.

The tie rod is about 3 inches too short. So 2 options now:

1. Buy the Rock Assault high steer kit.
2. Clean up an FJ40 axle.

Option one is an easier fix but $ I don't have...
Option two is time consuming but cheaper.

Option two is looking good.

 

check out pirate some more..theres a guy that made some chepo hi steer from stock steering parts..somethin like death hippy catchup build?? i dunno lemme check it out

 

aha found it...he used a stock tie rod and sleeved it...its on the first page..here ya go

 

Thanks yoterr! I appreciate the help!

Unfortunately this truck will be a DD and will require a safety inspection. In BC it is illegal to weld/cut or touch any steering components.
I think the best option will be to rebuild an FJ40 axle and i can just bolt up my newly rebuilt knuckles.

 

Looks like you have a sweet build going on. So how'd the JB weld work out for ya?

T_BONE