Can't find my previous post about this anymore so I'll start over.

I plan on replacing my 4R rear axle (OEM locker) with a LC80 rear axle with OEM locker. I allready purchased an axle plus most parts for the swap.
I allready have the 9 1/2" 4.88 LC gears. I started to set them up yesterday, a lot later than planned.
The reason I want to do this is:
a) I got the lC80 axle for cheap
b) I want the 'limp home mode" this axle has cause its a freefloater
c) OEM disc brakes and built in parking brake
d) much stronger R&P (I roates several third members), especially with the upcoming 2JZ swap.

A pic of the axle when I just hauled it in:



Here's a pic comparing the 4 cyl pinion (left) and the LC pinion (right)



Something odd: the pinion bearings of the LC are actually not as thick as a V6.



I finished cleaning the axlehousing. I want to cut off the longest side, shorten it and reweld it. I got a special machined steel axle which will act as a guidance.
I also plan on using a welding jig of some sort.

Next step is to make a few collars which I can weld into the axlehousing before I cut it in pieces. I will have to buy some material for that next week.
I also allready have another short side axle which will replace the long one,
When succesfull i will end up with a track similar to a '85 pickup rear axle. And with a centered third member.
I hope.

 

Just a thought- You mat be able to use an early FJ40 transfer case (73 and older) mated to your transmission via a marlin adapter and maintain the offset FJ80 axle. The only problem might be Gas tank clearance issues. If you have RHD it may not, Im not sure. I am curious, what is the difference in width between the two axles?

 

I am very interested in this swap. I want the lc80 axle for the locker and disc brakes. If you don't mind me asking how much did you pay? Granted it will be vastly different here, just trying to get a ball park. A few questions: With front and rear discs do you think that will be too much for the stock master cylinder? Maybe the lc one would be a better fit. You going to use the axles parking brake or stick with your all pro one? What kind of setup are you going to run in the rear? What other parts did you purchase for the swap?

 

I know its possible to swap tranny's so the driveshafts line up. I did that years ago on my Hilux. A Landcruiser 70 series also uses a R tranny and also has both driveshafts on the passengerside. So a Marlin adapter is OEM available over here.
I tried to find a pic but I think I either did not make one to begin with or lost it.
The guy I sold the Hilux still drives this setup. Maybe I can take a pic later today.

The rear axle widths I found on various models:
'85 Hilux 143 cm (56 1/4")
'90 4R 150 cm (59")
'90 LC70 143 cm (56 1/4")
'95 LC80 160 cm (63")
'02 LC100 173 cm (68")

I found the LC80 axle for $300. It was in badly rusted condition but since I'm hacking it up I did not care. I found another short inneraxle for $60. No other parts needed except for the materials for the jig.

I'm in doubt what to do with the parking brake. The all pro works just fine and it has no problem with dirt and mud. I'll make a decision later on in the project.

I allready have rear disc brakes, OEM locker and also the LC80 master cylinder. I am gone use this axle for my suzuki as soon as the LC axle is done.

I'll keep posting as soon as I have completed stuff.

 

Okay, the jig is almost done.
I'll pick some parts up this week and hope to have it shortened within a week or 2.

 

Lol 4runner4ever, do you still have the stock Dunlop crap tires?

My 4Runner came with those Grandtreks and where ˟˟˟˟˟...

I was wondering if you want free holydays in Spain paying with a LC70 SAS for my 4Runner hahahaha.

I'm OK with my rear axle

I envy you...

David

 

Update:
Finally found time to do some work again. After I cut my finger real bad this weekend. Slit it open over an inch when I stuck my finger in the slot I just made into the housing.
First thing I did tonight was de-burring and cleaning all parts.

Diff housing centered:


I still have to finish it but that will have to wait till this weekend. Only thing left to do is weld it properly, brace it from the inside and put back the stock reinforcement bracket. I will not be putting it under the 4R till I have my holiday in a few weeks.

Last note: this housing has a THICK wall. Took forever to make the cuts. Hope it also means it will last forever.
It's so heavy I think I'm gone weigh and compare both axles when I swap them.

I still have the dunlops (for some 12 years or so) which I use to move my projects and axles. Beats carrying my crap around my garage.

That is not my 4R, it's a samurai-toyota project. I finally have all the stuff and I started bolting it together a few weeks ago. I think I'm gone donate my old 7M-GE for it as soon as I got the 2JZ in.

 

are you going to have to get custom axles made since you shortened it?

 

No, I use 2 short axleshafts instead of a short and long one. They are in the pic so you can see the difference. Stop drinking and concentrate.

 

Oddly enough I was drinking, which creeps me out. How much did you shorten it by? How much of an increase in track will you have?

 

If everything goes as planned I should end up with 56 1/4".
The axle was 63".
I also plan on using track spacers like I have up front. This will add another 2 1/2".
My front is 59" (I think) and my rear wil be 58 3/4".
Measured from WMS-WMS.

And don't mind the remark. I was smoking when I replied.

 

I am familiar with FJ40s so here is another idea, The 40's and maybe 60's use a drum parking brake directly off the t-case that locks the rear driveshaft. Maybe something to look into.

 

Some progress made.
I finally got the backing plates back. Had them zinc plated cause they were badly rusted.
I'm gone stick with the all pro disc parking brake for now. Since it's allready on the gearbox and works just fine.
The track with from WMS-WMS is 1410 mm, as calculated.
Here's how it looks so far.

 

I'm so jealous... Really don't want free holydays in Spain?

Very nice work dude!

Smoke... Oh yes, you've it easier, you're dutch! Hahahaha

David

 

I'm allways in for a free holiday.

And a local guide allways comes in handy. Keeps me from trouble with the law.

And you are right. Its legal here if that's what you mean.

 

Really?

David

 

any more progress?

 

Well, yes, some progress, but not much. I have become a dad again last week.

Luckily tomorrow is my last day at work and my 3 week holiday starts.

I did find time to take the calipers apart, cleaned and painted them plus put in all new seals, grommets etc.

The diff is also setup.



I had a lot of problems with the setup. The LC80 gears I ordered from reider Racing are slightly different than the OEM gearset. This could be due to the fact that it's an OEM locker and not an open carrier.
It was impossible to adjust the backlash with even the smallest OEM shim, so I had a new shim milled down, had to wait a week for that, find out if it was the correct thickness by mounting it etc. Offcourse I was out of luck and I had to order some more shims from the dealer, take them to the shop for milling (or grinding or whatever they do with them) etc etc.
All in all it took weeks to finish. I ordered some 12 shims, had 2 special shims made and I think I did the setup some 10-11 times. These are the leftovers.



Luckily the gears do fit now and the carrier can still rotate without touching the diff housing.

Both driveshafts popped in witout any problem.

I wanted to order new disc this week so I can start next week with mounting the axle on the 4R. You guys are lucky living in the US. I searched everywhere and found rear discs for 90-110$.
I also checked locally in the Netherlands, Germany and Belgium, at several different shops and dealers, and these discs will set me back attleast 400$

 

cool stuff, congrats on the kid! Can't wait to see it finished

 

Started with the actual swap today.
The axle is ready, except for the brackets for the 5 link.

I did have to make a tool for adjusting the hub bearings properly:



Torqued them down to spec. I did not use new bearings since these look like new.



Calipers, new discs and some gay rustprimer on the diff.



Time to rip the axle out:



Space to work on. I think I will do some rustprevention also. It starts to look bad and now I have easy access.



Removing of the brackets I need:



And the brackets cleaned and preped for tomorrow:



I will have to pick up some steel tomorrow cause I have to fab the 2 lower brackets.

I'm also planning on making the 2 upper brackets for the links longer so the short links will be more horizontal than they now are. I tested the travel today and the only thing limiting the travel are the 2 upper (short) links. And the swaybar. I'll make some disconnects for it, or buy another Nissan electric disco.

I have to sleep a while on changing the brackets/links. I'm not sure how this will effect the geometry. Maybe I will stick to what I have now and do the finetuning later.

I also considered a 3 link but that will most likely get me in trouble with my yearly inspection. Which is next thursday

Sorry for the huge pics, I think I'll have to dig into the manual of my Cybershot.