Elotsip - Toyota Axle Swap

[4RnrRick]

Well a buddy of mine (Elotsip / Billy) wanted some help swapping Toyota axles under his Sami (which was currently running a TT YJ kit with sami axles and a 1.6L 16 valve engine) - so I offered my services. I've never really done much with the sami's as far as building one, but I've dealt alot with the Toyota's - So we will see how this goes. After some research and several months of collecting parts, it was time to dive into it.... And if you guys know how I like to do build up threads, Hang-on because this one is going to go fast (I hope)!

Here is how I found his garage after work today ... :shaking:

http://www.pirate4x4.com/forum/attachment.php?attachmentid=255439

http://www.pirate4x4.com/forum/attachment.php?attachmentid=255440

It really didn't take too long to clean it up.....

http://www.pirate4x4.com/forum/attachment.php?attachmentid=255441

Then we gathered his pile of parts together for the new rear axle. :grinpimp:

http://www.pirate4x4.com/forum/attachment.php?attachmentid=255442

Sky's Offset Rear housing
Shorten toyota shaft
T-100/Tundra Long side shaft
Sky's axle perches
Sky's U-bolt Flip
Sky's Disc brake conversion
Monte carlo calipiers with banjo bolts
Bored Chevy Rotors
Sky's SS braided lines
Monte carlo Brake pads
Monte carlo calipier pins
Toyota 4:10 3rd member
Lockright
New seals and bearings

http://www.pirate4x4.com/forum/attachment.php?attachmentid=255443

We started to tear into the diff to install the Lock right but we found rust on about 1/4 of the teeth on the ring gear - so we stopped that. time to find another 3rd - this was suppose to be a good useable 3rd!!

[4RnrRick]

I forgot to take a good before picture, so this will have to do for now. got to love a three car garage. plenty of room for a ton of parts and a sami sideways in it.....

http://www.pirate4x4.com/forum/attachment.php?attachmentid=255444

We had some trouble with a couple nuts on the u-bolts, so we just cut them off!

http://www.pirate4x4.com/forum/attachment.php?attachmentid=255445

BTW did I mention that it was 90 degrees and just about 100% humidity here! All evening long it was trying to rain - and this is Oregon, Its not suppose to feel like the deep south!!! We aren't use to this type of weather - Damn.... Man is it HOT!!!!

Rear axle is gone!

http://www.pirate4x4.com/forum/attachment.php?attachmentid=255446

Rear axle, driveline, traction bar..... PM "elotsip" if your looking for sami axle parts!

http://www.pirate4x4.com/forum/attachment.php?attachmentid=255447

Next up was to install the RockRat driveline adapters and a Toyota CV shaft for mocking up the new rear driveline angles....

http://www.pirate4x4.com/forum/attachment.php?attachmentid=255448

[4RnrRick]

And this is what we found! :mad3: Every bolt in the kit was too long! Well except one of them but that one was too short! we where supplied (15) 3/8-16 unc x 1" hex head cap screws and (1) 3/8-16 unc x 3/4" . The 1" longs bolts would have been fine if the adapter was another 0.070"-0.090" longer. We had to end up grinding the bolts down to make them flush. I was really shocked to find this problem because I have heard nothing but good news about these adapters.

http://www.pirate4x4.com/forum/attachment.php?attachmentid=255450

http://www.pirate4x4.com/forum/attachment.php?attachmentid=255452

http://www.pirate4x4.com/forum/attachment.php?attachmentid=255451

After we got that done. we bolted up the new rear axle housing using the perches and the new u-bolt flip plates. then we centered the axle from side to side and tighten the u-bolts down slightly. then we installed the 3rd member and put the vehicle's weight on the rear axle. then we just matched teh driveline angle to the flange angle using a angle finder.

http://www.pirate4x4.com/forum/attachment.php?attachmentid=255453

Once we where satisfied that the angles where correct we then tack welded teh perches into place - but not before double shecking out side to side meaurements one more time.

http://www.pirate4x4.com/forum/attachment.php?attachmentid=255454

[4RnrRick]

Then we pulled the axle housing out from under it and cut up some flat bar to cap the ends of the spring perches. Then we welded the spring perches on (inside and out), the caps for the perches and then finally the diff armor (via Trail-Gear).

http://www.pirate4x4.com/forum/attachment.php?attachmentid=255456

So thats all that we gone done tonight which was about 5 hours worth of work. Tonight I believe Billy is going to be painting the axle housing, ubolts, flip plates and disc brake brackets.....

Also in the future we will be adding a axle truss and the rear shocks mounts.

So stay tuned - more will get updated tomorrow (saturday) evening!

And heres a decent before picture of Billy just two weeks ago on the trail......

http://www.pirate4x4.com/forum/attachment.php?attachmentid=255457&stc=1&d=1153551642

[elotsip]

Thanks Rick, nice write up so far. I got all the brackets and rear axle sprayed with black Hammerrite spray paint. This stuff is pretty durable and has the 'powder coated' finish.

[WA-HCRC]

sweet guys. any plans on more WB? lookin really good so far. :D

[GrimWHeeler]

Looks good guy's.. and a bit sweaty there too hahaha

I bet I know somebody that would buy those sami spacers from you.. he he

[4RnrRick]

Currently there are no plans for strecthing the WB. The main goal right now is to swap in the Toyota axles (with all fresh bearings and seals) and to convert the steering over to use a FJ-80 box.

I do know that he would like a longer WB.... maybe even a strecth to a LWB sami (so he could buy a factory top) with some tub and frame work.

[RocKrawler]

looking good so far, wanna come down & help me clean my garage too?

[purevil71]

Nice works so far.....keep us updated on your progress!

[4RnrRick]

Time for the Saturday evening update.....

Got the shrokworks rear tire carrier modifed to hold the new 6 lug on 5 1/2" rims. just ground off the old studs and installed (2) new ones.

http://www.pirate4x4.com/forum/attachment.php?attachmentid=255547

Got the old bearings & seals pressed off and new ones installed.... That only took a couple trips to teh press since the first time Billy got teh seals and bearings back at his house... :laughing:

http://www.pirate4x4.com/forum/attachment.php?attachmentid=255545

The rear axle is now ready for assembly.

http://www.pirate4x4.com/forum/attachment.php?attachmentid=255546

Got the extra casting tab ground off the monte carlo calipers so they fit the sky's disc brackets correctly... ( you got to do that on about 50% of the castings.....

http://www.pirate4x4.com/forum/attachment.php?attachmentid=255548

Also got Sky's brake lines routed to the factory tee and up to one of the factory sami brackets. we just capped off one of the brake lines coming out of the suzuki combination valve (I think that is what it is...)

http://www.pirate4x4.com/forum/attachment.php?attachmentid=255549

[4RnrRick]

We also had to grind off part of the calipier near the banjo bolt to be able to put the brake lines at a slight angle becasue I did not like how kinked they would have to be with a un modifeid caliper.

Driver side:
http://www.pirate4x4.com/forum/attachment.php?attachmentid=255550

Passenger side:
http://www.pirate4x4.com/forum/attachment.php?attachmentid=255551

Fully assemblied with 4:10 gears and a lockright.
http://www.pirate4x4.com/forum/attachment.php?attachmentid=255552

And its a roller again!
http://www.pirate4x4.com/forum/attachment.php?attachmentid=255553

And tire stick out..... 15x10 rims with 4" BS and 33X14.50X15 boggers.
http://www.pirate4x4.com/forum/attachment.php?attachmentid=255554

[4RnrRick]

After talking to Sky, we just decided to run that ring gear that has some rust on the teeth. So we installed a Lock right into it and threw it in the pile of good parts....

http://www.pirate4x4.com/forum/attachment.php?attachmentid=255559

Sami front axle removed.

http://www.pirate4x4.com/forum/attachment.php?attachmentid=255560

Hence its not a roller any more.....

http://www.pirate4x4.com/forum/attachment.php?attachmentid=255561

And next up is the front axle build.....

http://www.pirate4x4.com/forum/attachment.php?attachmentid=255562

So today we spent about 14 hours working on it.... but 3-4hours of that was running around chasing down little crap, nuts and bolts, some toyota only parts, another diff, fluids, swaping tires and rims ans just crap like that. not to mention the there was probably another 1 to 1.5 hours BS'n with some freinds. More to follow tomorrow.....

[WA-HCRC]

sweet work guys. lookin good man. hopefully soon i'll be able to wheel with ya in oregon, think im moving down to salem soon. got some family there, and im gettin tired of the washington thing :D got a sammi on yota's now too :flipoff2: :D

[4x4ing_Jeanella]

Thanks Rick, nice write up so far. I got all the brackets and rear axle sprayed with black Hammerrite spray paint. This stuff is pretty durable and has the 'powder coated' finish.


Hey Bill, its looking good! I am ready to go back to Maob next year but lets go in maybe Oct/Nov. Had great fun though!! Might come up there and 4wheel with ya. It was a spring that broke on my clutch so its getting fixed now. Great Write up Rick! Catch ya later your sis, Jeanie :cool2:

[Snakeman]

Looking good Bill, Can't wait to see it on the trail!

What are you going to do for a rear traction bar?

[TNToy]

Any plans to deal with the front/rear brake bias?

I'm running the small chevy calipers in back and IFS Toy ones up front. No proportioning valve anywhere. It's a little, er, exciting in wet weather. Tap the brake pedal and the rears lock up.

But man, does it stop fast in 4WD. :eek:

I know you ran this same brake setup in your 4Runner with a (not-too-helpful) Wilwood rpoportioning valve, but I haven't seen any mention of it in here, or on the Quasimodo buildup.

I assume you figured out some sort of fix if you're running it on this build, too. Or are you just living with it?

I found the perfect rear calipers I would have loved to use - off of a rear-disc brake Volvo (I work at a Volvo dealership). It was a rear-disc caliper that's half the size of the S10/Monte Carlo caliper, with a similar mount so it'd be easy to fab a bracket. With a smaller caliper you'd be able to get the proper F/R bias with a manual prop. valve...

But I couldn't find a ~1/2" thick solid rotor that'd work with those humongous flanges on the rear Toy axleshafts...

[4RnrRick]

What are you going to do for a rear traction bar?

I'm not sure what Billy is planning right now, we might try to reuse what he had before, or we could build a new single bar setup right off the top of the diff.

Any plans to deal with the front/rear brake bias?

Haven't gotten that far yet.... but he did order a Line lock for a parking brake.

I know you ran this same brake setup in your 4Runner with a (not-too-helpful) Wilwood rpoportioning valve, but I haven't seen any mention of it in here, or on the Quasimodo buildup.I assume you figured out some sort of fix if you're running it on this build, too. Or are you just living with it?

Well this isn't my build, its Billy's - I'm just helping. But for right now there is no plans on doing anything. I've never dealt with it hands on with a sami - so I don't know what to expect. But we will see what happens. The only thing that I told him to do was to buy the nicest set of semi metallic brakes pads up front he could find and the cheapest set out back..... The braking on Quasimodo is better than it was on my 4runner was but its still not right. And for that I'm just using the 2wd Combination valve but I have plans to install the wildwood adjustable unit back in line.

[4RnrRick]

Billy got all the power steering removed.... Sidekick box, Sidekick Pump, 1.6L 16 valve bracket & Reservior (to make room for a FJ-80 box setup.)

http://www.pirate4x4.com/forum/attachment.php?attachmentid=255647

Heres some passenger side conversion plates I designed and had burnt out to adapt the Toyota 29" perch centers to 28 1/4" perch centers on the Sami. And more specifially for using YJ springs which are 2 1/2" wide compared to the 2" wide stock sami springs. Billy's rig already had the TT YJ conversion, so we are just adapting to that kit. For the driver side, just cut the stock perch off and replaced it with a new perch moved over 3/8".

http://www.pirate4x4.com/forum/attachment.php?attachmentid=255648

http://www.pirate4x4.com/forum/attachment.php?attachmentid=255649

Then I aligned the adapter plate and tack welded it on and the driver side perch. then we bolted it up to make sure everything would fit correctly. I had already did several revisions to my oringal design and even made a couple wood prototypes (easy to cut wood) to make sure I had the best design possible before we made them out of steel. and it looks like that work paid off, because everything fit great!

http://www.pirate4x4.com/forum/attachment.php?attachmentid=255650

http://www.pirate4x4.com/forum/attachment.php?attachmentid=255651

[4RnrRick]

More mock up pictures.....I really couldn't be happier with the prototype brackets , they fit better than I expected!

http://www.pirate4x4.com/forum/attachment.php?attachmentid=255652

http://www.pirate4x4.com/forum/attachment.php?attachmentid=255653

The diff even clears by a country mile!

http://www.pirate4x4.com/forum/attachment.php?attachmentid=255654

Then we pulled it all back out to finish building a very stout housings that will be able to take some abuse...Heres the specs on the housing.

83 Toyota front housing
4RnrRick's prototype Perch brackets (passenger side)
Sky Axle Perch (passenger side)
Sky flip kit (driver side)
Trail-Gear Diff armor
Trail-Gear Axle Truss
Marlin Knuckle Ball Gussets kit
Re-enforced Spring perches
4:10 gears with a Lock Right

http://www.pirate4x4.com/forum/attachment.php?attachmentid=255655

http://www.pirate4x4.com/forum/attachment.php?attachmentid=255656

BTW I really like the Marlin's Knuckle Ball Gussets! they are made from 3/8" plate and they fit really nice! definately work the money!

[4RnrRick]

Just a couple more....

http://www.pirate4x4.com/forum/attachment.php?attachmentid=255659

http://www.pirate4x4.com/forum/attachment.php?attachmentid=255660

And then we got it painted and installed (once again) under the rig.

http://www.pirate4x4.com/forum/attachment.php?attachmentid=255661

http://www.pirate4x4.com/forum/attachment.php?attachmentid=255662

We spend about 6 hours working on it today. and I decided I had enough of the heat (102 F) so I called it a day... We had not gotten as far as I hoped since we ran into more little problems than I had expected and I'm sure Billy must be up to about 10-15 trips to the different stores just over the last 3 days getting all the little crap.

[antt]

looking good, nice buildup thread :smokin:

[Hvy_Chevy]

are the front perches the same height? I thought stock the pass side was like 3/8" higher than driver side, and you put another 1/4" or 3/8" plate on top of that

[4RnrRick]

After everything was said and done, the driver side perch was only a 1/4" lower and we didn't worry about that. Remember that the OEM driver side perch was cut off and a new "tall" one was welded on (which was one of Sky's generic axle perches, but just 3/8" closer to the diff.

[zc911]

very very nice work.
I jsut got my front axle on properly, i moved the diff side perch, and i was jsut able to squeeze in 2 u bolts :)
Did you check you caster? Mine is only about 1 deg, and i was told 5-6 would be optimal for better steering
I have the RR YJ kit

[4RnrRick]

No, we haven't checked caster yet - but thats easy to tweak with shims since we are still using the factory passegner side perch with just a adapter plate...

[zc911]

when i had my axle on with plates ( No where near as nice as yours lol) i had to add a 1 inch block for the palte to clear the diff, so my crossover steering did not clear the spring pack (5 leaf Yjs). And my caster at that time was 0 deg.
I was going to turn my kucles instead of adding shims, but now you got me thinking about shims lol much easier

[4RnrRick]

For all those interested (since I gotten PM's asking about them), these plates will be available through Sky-Manufacturing in the near future and pricing has not yet been determined....

http://www.pirate4x4.com/forum/attachment.php?attachmentid=255648

http://www.pirate4x4.com/forum/attachment.php?attachmentid=255660

http://www.pirate4x4.com/forum/attachment.php?attachmentid=255654

[4RnrRick]

We had to trim down the Marlin Gussets to make them clear the seal plates! :mad3:

http://www.pirate4x4.com/forum/attachment.php?attachmentid=255959

http://www.pirate4x4.com/forum/attachment.php?attachmentid=255960

http://www.pirate4x4.com/forum/attachment.php?attachmentid=255961

So if you buy this kit, shave it down like this BEFORE you weld it on....

http://www.pirate4x4.com/forum/attachment.php?attachmentid=255977

Billy got a TOO little to ambitious with the grinder when he was cleaing up the brackets off the oringal axle and ended removing the orignal steering stops :shaking: , So we just made some.

http://www.pirate4x4.com/forum/attachment.php?attachmentid=255962

[4RnrRick]

then I showed Billy the fun of Birf rebuilding.....

http://www.pirate4x4.com/forum/attachment.php?attachmentid=255963

http://www.pirate4x4.com/forum/attachment.php?attachmentid=255964

we took a break from the grease and got the spindle installed....

http://www.pirate4x4.com/forum/attachment.php?attachmentid=255965

Then it was back to the grease to rebuild a set of Aisan Hubs. For reference here is a article showing how to properly assemble the hubs.
Rebuilding 1979-1985 Toyota Manual Locking Hubs
http://www.pirate4x4.com/forum/showthread.php?t=281879

http://www.pirate4x4.com/forum/attachment.php?attachmentid=255966

And then we had fun with hand packing a new set of wheel bearings, installing new seals and then we got the hub body installed.

http://www.pirate4x4.com/forum/attachment.php?attachmentid=255967

Unfortionately we had to stop there because Billy got this axle with Warn hubs and the Aisan replacement ones he got off Ebay didn't come with cone washers... All of that took about another 5 hours last night. and Billy still has the driver side to assembly.

[TNToy]

It looks from the pictures like you let him use horrible 'turns to liquid' black grease in there. You must really hate him. :flioff2: :D

Are those stock birfs and shafts? It's so weird to try and wrap my brain around wheeling WITHOUT longfields, but when you're that light and the motor is that small... why not? :)

[epike7915]

What "bored out" chevy rotors did you use for the rr discs? And what did you exactly "bore" out? The center hole?
Awesome write up by the way.
Thanks,

Eric

[4RnrRick]

It looks from the pictures like you let him use horrible 'turns to liquid' black grease in there. You must really hate him. :flioff2: :D

Thats all he had and I didn't happen to think about it at the time..... Oops:rolleyes:





Are those stock birfs and shafts?

Yeap - they are stock since right now is is planning on sticking to 33"s. I told him if he goes up to 35"s he should think about upgrading to a Ring'd & Cryo Birf.





What "bored out" chevy rotors did you use for the rr discs? And what did you exactly "bore" out? The center hole?

He just picked them up from Sky already modified. But they are commonly 89 Chevy 1500 Regular Cab 4x4 front rotors (1" thick). Have to be the Regular cab rotors as the Ext. cab rotors are 5/16" thicker. For the short side which uses a toyota mini shaft they need to be bored out to 106 mm (4.173"), but the long side is from a Tundra/T100 and they require a larger bore and I don't know what it is. Maybe Billy chould measure his. Since he just bought them from Sky. Sky had already taken care of this detail with the rotors needing different size holes in them.

BTW - read this:
Rear Disc Brake FAQ
http://www.pirate4x4.com/forum/showthread.php?t=281059

[epike7915]

Thanks!

[elotsip]

Got all the hardware in today to finish up the front axle. I should get it done tonight, assuming I can remember how it goes together! haha.

[4RnrRick]

Billy got the rest of the front axle assemblied last night.

http://www.pirate4x4.com/forum/attachment.php?attachmentid=256278&stc=1&d=1154094554

And here it is with the bogger installed...
15x10 rims with 4" BS and 33X14.50X15 boggers.

http://www.pirate4x4.com/forum/attachment.php?attachmentid=256279&stc=1&d=1154094554

Items left to finish......
Move Rear Axle back 1"
Rear Axle Truss
Rear Shock mounts (axle side)
Rear Traction Bar
Axle Gear oil
-
Modfiy Rear Driveline
Modify Front Driveline
-
Move Front Axle Forward 1"
Front BrakeLines
Front Shock Mounts (frame side)
Axle Gear oil
-
Install FJ-80 Box
Install HighSteer
PSC Power steering
Bleed System
-
Replace MC with bigger unit
Install Line Lock
Bleed System
-
Trim Fenders
Install Bushwacher Fender flares


So there is just a bit left to do.....

[dr_claw]

What master cyl. are you going with?

Firebird / Camero?

Post up some pics 'cause i will be doing this soon too.

[4RnrRick]

What master cyl. are you going with?


Curently we still are not sure - we are going to the wrecking yard Saturday to look for a bolt-in Aisin....

Ref: http://www.pirate4x4.com/forum/showpost.php?p=5735397&postcount=14

[elotsip]

I just picked up Sky's Toyota High Steer kit as well as some misc peices to fab up my traction bar mounts and shock mounts.

Should be a productive weekend!

[4RnrRick]

Got the rear shock mounts figured out. These are Sky's generic shock mounts.

http://www.pirate4x4.com/forum/attachment.php?attachmentid=256448

Got the old ford shock mounts removed (they were poorly installed) and cleaned up the frame

http://www.pirate4x4.com/forum/attachment.php?attachmentid=256449

Sky's High Steer Installed, cut the inner fender wheel out and started mocking up the FJ80 steering box and pitman arm. The FJ-80 arm is REALLY long. We are getting about 10 1/2" of stroke out of it on the draglink but we only require about 6" for this setup. through some measuring I found that we really only need a arm about 5 1/4" long to get the stroke we need.

http://www.pirate4x4.com/forum/attachment.php?attachmentid=256450

Well looking through my picture archives I found this. The 2wd 3rd gen toyota arm is about 5 1/2" long and really flat and the same taper! so we are off to the wrecking yard to go pull one! Because it will be the perfect fit!

http://www.pirate4x4.com/forum/attachment.php?attachmentid=256451

We also almost got the traction bar finished and got started on the truss for the rear axle, but there no point in showing pictures of those only half complete.

[Hvy_Chevy]

what fittings does the FJ box use?
I've got a tracker pump and a IFS box... need a high pressure hose...

[cr430c]

awesome work

[jovibuilt]

I have a quick question.Reading all over the net sammy front spring perches are 28.5 center to center and toyota are 29.why did you space the spring mounts in 3/8 on each side wouldn't 1/4 be enough?I am getting ready to do this swap myself.Thanks

[4RnrRick]

what fittings does the FJ box use?


Toyota Fittings!?.... Seriously thou - we are not to that point yet....





Reading all over the net sammy front spring perches are 28.5 center to center and toyota are 29.

Not from my research and what I measured.... The sami perches are 28.25 center to center.....

[4RnrRick]

Well we got the Brake Master Cylinder figured out today. For all the little details - Read about it HERE (http://www.pirate4x4.com/forum/showthread.php?t=495302) Its from a 93' Mazda 929, 3.0L V6, 4 wheel disk brakes with ABS & a 1" bore MC which has Metric Fittings, Low level switch and was a bolt-on to the Sami Brake Booster.

http://www.pirate4x4.com/forum/attachment.php?attachmentid=256552&stc=1&d=1154236182

http://www.pirate4x4.com/forum/attachment.php?attachmentid=256553&stc=1&d=1154236182

We also installed a Electric Line lock into the front brake line.

http://www.pirate4x4.com/forum/attachment.php?attachmentid=256554&stc=1&d=1154236182

And we also found the pitman arm we are going to use. Its from a 3rd Gen 2wd Toyota Truck with Power Steering.

http://www.pirate4x4.com/forum/attachment.php?attachmentid=256555&stc=1&d=1154236182

http://www.pirate4x4.com/forum/attachment.php?attachmentid=256556&stc=1&d=1154236182

From there I had to leave Billy's, But I know he was working on finishing up the Rear Traction bar, Rear Truss & the PS box mounting.

[Snakeman]

...Not from my research and what I measured.... The sami perches are 28.25 center to center.....

Keep in mind, this is on a sami w/ a TT YJ conversion.

Don't know if it makes a difference or not....

[4RnrRick]

Doesn't make a difference.... the springs pins are still in the same location on the Stock Sami front axle.

[4RnrRick]

Steering box mounts drilled and tacked into place. (3/16 plate with no frame sleeves.)

http://www.pirate4x4.com/forum/attachment.php?attachmentid=256702&stc=1&d=1154353725

http://www.pirate4x4.com/forum/attachment.php?attachmentid=256703&stc=1&d=1154353725

http://www.pirate4x4.com/forum/attachment.php?attachmentid=256704&stc=1&d=1154353725

Rear Axle Truss and traction bar mount tacked into place.

http://www.pirate4x4.com/forum/attachment.php?attachmentid=256705&stc=1&d=1154353725

Rear Traction bar and a slightly modified Skys traction bar crossmember.

http://www.pirate4x4.com/forum/attachment.php?attachmentid=256706&stc=1&d=1154353725

[4RnrRick]

http://www.pirate4x4.com/forum/attachment.php?attachmentid=256707&stc=1&d=1154353993

Steering box mount fully welded

http://www.pirate4x4.com/forum/attachment.php?attachmentid=256708&stc=1&d=1154353993

Rear Axle Truss and traction bar mounts fully welded.

http://www.pirate4x4.com/forum/attachment.php?attachmentid=256709&stc=1&d=1154353993

And its painted...

http://www.pirate4x4.com/forum/attachment.php?attachmentid=256710&stc=1&d=1154353993

Traction bar crossmember installed.

http://www.pirate4x4.com/forum/attachment.php?attachmentid=256711&stc=1&d=1154353993

The tiny steering shaft is made....

[4RnrRick]

Steering shaft installed.

http://www.pirate4x4.com/forum/attachment.php?attachmentid=256712

Traction bar installed.

http://www.pirate4x4.com/forum/attachment.php?attachmentid=256713

Rear axle installed.

http://www.pirate4x4.com/forum/attachment.php?attachmentid=256714

Front brake lines (we just reused the sami rears.)

http://www.pirate4x4.com/forum/attachment.php?attachmentid=256715

Ford Shock mounts.

http://www.pirate4x4.com/forum/attachment.php?attachmentid=256716

[4RnrRick]

Everything installed up front.

http://www.pirate4x4.com/forum/attachment.php?attachmentid=256717

Overall pictures.

http://www.pirate4x4.com/forum/attachment.php?attachmentid=256718

http://www.pirate4x4.com/forum/attachment.php?attachmentid=256719

Then we flex it some.

http://www.pirate4x4.com/forum/attachment.php?attachmentid=256720

Great pitman arm clearance.

http://www.pirate4x4.com/forum/attachment.php?attachmentid=256726

[4RnrRick]

Since we moved the front axle forward 1" - Billy has some trimming he needs to do on the fenders....

So thats all for now. Not bad for about 10 days worth of work.....

[TheBanjoman]

Since we moved the front axle forward 1" - Billy has some trimming he needs to do on the fenders....

So thats all for now. Not bad for about 10 days worth of work.....


Just don't forget the lugnuts.......:smokin:

[4RnrRick]

We wrote up a list of things that still need to be finished, and done worry, more lug nuts were on the list! Maybe Billy will post up that list. I don't have a copy of it.

[elotsip]

Sure thing. Here's the list of out standing items:
1. get front drive lines made. Using 2.5" schedule 40 pipe.
2. add gear oil to front and rear diffs
3. shorten bolts for rock rat adapters
4. install low profile drain plugs
5. bleed brakes
6. get and install bump stops
7. redo exhast and muffler
8. wire in low level brake fluid switch
9. wire in line lock switch
10. get power steering adapter bracket for 1.6l 16v
11. install pully on pump
12. determine location for PS res
13. consider PS cooler
14. determine high and low pressurelines for power steering
15. replace fan clutch
16. mount radiator
17. get PS high and low pressure lines
18. zip tie front brake lines
19. finish breather vents
20. install lug nuts
21. get/install brake line clips
22. install fender flares and mud flaps
23. determine fix for cross member in front or Tcase
24. bolt check.

[FLEXYSAMMY]

Very nice build! Every thing looks very clean and done rite! But I have to ask how in the hell do you take apart a burf like that??????


http://www.pirate4x4.com/forum/attachment.php?attachmentid=255963

[txzuk1988]

#23 determine fix for crossmember infront of t case.......

One call to Rock Rat for his crossmember! Simple and effective!

Nice build up

[Wheelie_Pete]

Very nice build! Every thing looks very clean and done rite! But I have to ask how in the hell do you take apart a burf like that??????

Even the rotten old Haynes manual shows you how to do it. Get a brass drift, a vise, and a 3lb sledge. You roll up the inner star until you can pop out a bearing, then go to the opposite side and pop out another one. It's not too hard. It's actually a pretty amazing little feat of engineering design though how it's all put together.

[elotsip]

#23 determine fix for crossmember infront of t case.......

One call to Rock Rat for his crossmember! Simple and effective!

Nice build up

Is that the High Clearance Trans Mount? If so thanks! I have always wondered what that kit was for...

Thanks,
Billy

[TheBanjoman]

Is that the High Clearance Trans Mount? If so thanks! I have always wondered what that kit was for...

Thanks,
Billy

Its a good design and allows you to cut out the crossmember so that you don't have driveshaft problems.

It was designed to be bolt on, and for some that is OK but I found that I didn't like the lack of clearance on right side with all the brake/fuel lines.

The kit was designed well enough to allow you to weld the mount to the frame and not have to deal with the set of bolts on both sides of the frame.

I cheated when I put mine on. I was removing a 2" body lift so I just took the Bend-Pak lift and raised the body up a few inches a side at a time to give me clearance to weld them on. That way I could lay beads on top of the frame as well to make the mount even stronger.

No complaints.

[rotozuk]

Even the rotten old Haynes manual shows you how to do it. Get a brass drift, a vise, and a 3lb sledge. You roll up the inner star until you can pop out a bearing, then go to the opposite side and pop out another one. It's not too hard. It's actually a pretty amazing little feat of engineering design though how it's all put together.

Never had mine apart either.. Well, not on purpose. I was able to get a few runs on stock Toy birfs on mine with a bigger engine and 37" tires, so probably be fine for a while with your set up.

Nice clean work guys. Nice to see a good Sammy build up again.

-Wayne

[elotsip]

Well got a bit more work done. It was a long week at work. Worked until 8 just about everyday and then had to work Sat and Sun as well. Oh well. So here's where I'm at...

Rick and I cut out the old cross member that supported the tcase and the trans and fabbed up an 'S' shape support bar out of some flat bar. We added a support to it as well just in case. With the slip yoke at the tcase I have plenty of room for flex.
http://img.photobucket.com/albums/v495/elotsip/Trucks/sammy%20axle%20swap/2006_0806Image0001.jpg

http://img.photobucket.com/albums/v495/elotsip/Trucks/sammy%20axle%20swap/2006_0806Image0002.jpg


Got the front drive line mounted. I had the drive lines rebuilt using 2.5" schedule 40 pipe.
http://img.photobucket.com/albums/v495/elotsip/Trucks/sammy%20axle%20swap/2006_0806Image0003.jpg


I had to redrill the rear third member flange for 10mm bolts as it was currently setup for 8mm bolts.
http://img.photobucket.com/albums/v495/elotsip/Trucks/sammy%20axle%20swap/2006_0806Image0005.jpg


While I was working I made four spacers for my radiator as it was sitting awefully close to the fan.
http://img.photobucket.com/albums/v495/elotsip/Trucks/sammy%20axle%20swap/2006_0806Image0004.jpg


Finally we took it for a test drive. Mind you it was front wheel drive only without power steering. Only issue was the rear caliper rubbing on the inside of the wheels. We ground down the caliper just enough to clear the wheel and the rest looked good.
http://img.photobucket.com/albums/v495/elotsip/Trucks/sammy%20axle%20swap/DSCF0047.jpg

http://img.photobucket.com/albums/v495/elotsip/Trucks/sammy%20axle%20swap/DSCF0049.jpg


Tomorrow I'll be dropping the rear drive line off to get the 10mm flange installed in place of the 8mm flange. Then I should be good to go for a real test drive.

I still don't have power steering as PSC didn't ship my bracket. I ordered it Tuesday and as of Friday it still hasn't shipped. I called Friday and they promised it ship it that day but it didn't go out... Hopefully I get it soon so I can get the steering finished up.

[ZukIzzy]

Bill that looks great you have come a long way in a short time.

Wayne

[elotsip]

Hey Wayne,
Great to hear from you man! Still got your cage! Thanks for the comments. Can't wait to try it out. Got the rear drive line fixed today so tonight I will be able to take it for a real test drive.

[elotsip]

I got my PS hooked up today. Boy does it make a huge difference.
I'm using a FJ80 steering box, PSC pump and bracket, & Toyota IFS res. I added a cooler while I was setting it all up.

http://img.photobucket.com/albums/v495/elotsip/Trucks/sammy%20axle%20swap/2006_0813Image0001.jpg

http://img.photobucket.com/albums/v495/elotsip/Trucks/sammy%20axle%20swap/2006_0813Image0002.jpg

[Rockrat]

Billy I just ran across the thread here and noticed you were given the wrong Bolt kit.. I wish you would have called or if you did, left a message. I would have and if you still want will send the correct ones to you in the mail, on my dime..Not that its a money thing it was a convienence You purchaced the kit you should have been sent the right parts.. -Scott
Owner
Rock 4X Fabrication,LLC
1-847-544-1823
Or P/M and I will call you at your convienence

[elotsip]

It wasn't a big deal. I just cut the bolts down to size. The adapters themselves were a great fit and look very very good.

So it's cool, no problem.

[Rockrat]

I have cut down bolts in a pinch and it is still time consuming. At least get me yours and Ricks Shirt size I will send each one of you a logod shirt.

[elotsip]

I figure an XL would work for us both. Thanks a lot Scott. I appreciate it. I can always us a good shirt!

Thanks,
Billy

[supazuk94]

I have cut down bolts in a pinch and it is still time consuming. At least get me yours and Ricks Shirt size I will send each one of you a logod shirt.
now that's customer service..... :smokin:

[Rockrat]

I figure an XL would work for us both. Thanks a lot Scott. I appreciate it. I can always us a good shirt!

Thanks,
Billy

Expect them in th email.

[blue5.0]

Expect them in th email.
:beer: Cheers to that. Rockrat will get my next order. I don't know for yet, but customer service like that deserves support.

Good on ya!

[Gonzalo Bravo]

Well got a bit more work done. It was a long week at work. Worked until 8 just about everyday and then had to work Sat and Sun as well. Oh well. So here's where I'm at...

Rick and I cut out the old cross member that supported the tcase and the trans and fabbed up an 'S' shape support bar out of some flat bar. We added a support to it as well just in case. With the slip yoke at the tcase I have plenty of room for flex.


http://img.photobucket.com/albums/v495/elotsip/Trucks/sammy%20axle%20swap/2006_0806Image0002.jpg



Tomorrow I'll be dropping the rear drive line off to get the 10mm flange installed in place of the 8mm flange. Then I should be good to go for a real test drive.

I still don't have power steering as PSC didn't ship my bracket. I ordered it Tuesday and as of Friday it still hasn't shipped. I called Friday and they promised it ship it that day but it didn't go out... Hopefully I get it soon so I can get the steering finished up.

That mark on the driveshaft was during installation or the driveshaft is hitting something?

[elotsip]

yeah, just from rolling it around while the paint wasn't quite dry.

[4RnrRick]

Billy I just ran across the thread here and noticed you were given the wrong Bolt kit......

I'm glad to see that it was just a simple shipping mistake. And thanks for responding to the thread because I was still confused about how everyone loves the adapters and we ran into a problem like this.

I have cut down bolts in a pinch and it is still time consuming. At least get me yours and Ricks Shirt size I will send each one of you a logod shirt.

Thanks....

[Rockrat]

I'm glad to see that it was just a simple shipping mistake. And thanks for responding to the thread because I was still confused about how everyone loves the adapters and we ran into a problem like this.



Thanks....

I have implemented new policy. When the adapters come out of the machine the bolt kits will be wrapped up at that time, so as not to be pulled from the wrong drawer. When you go to the bolt bin now the bolts are sized left to right smallest to largest and yours were just pulled from the wrong one. Anyway shirts are in the mail.
-Scott

[SirMrManGuy]

Expect them in th email.
If you figured out how to send objects through email you must be one hell of a fabricator.

[OKIE ZUK]

That's Scott:laughing: .

[nose]

...

And we also found the pitman arm we are going to use. Its from a 3rd Gen 2wd Toyota Truck with Power Steering.

http://www.pirate4x4.com/forum/attachment.php?attachmentid=256555&stc=1&d=1154236182

http://www.pirate4x4.com/forum/attachment.php?attachmentid=256556&stc=1&d=1154236182

From there I had to leave Billy's, But I know he was working on finishing up the Rear Traction bar, Rear Truss & the PS box mounting.

Hi,

Sorry to hijack this older thread. I have not found this info on the www (I am not very good at searching...).

Can anyone please tell me what model year the 3rd generation 2wd Toyota PU is where the steering arm came from (see pic above)?

Thanks in advance.

Norbert

[bobjohnson]

Toyota minitruck 4x4 Generations are:
1st 79-83
2nd 84-89
3rd 90-95

I would guess 90-95 is what Rick is referring to here.

[nose]

Toyota minitruck 4x4 Generations are:
1st 79-83
2nd 84-89
3rd 90-95

I would guess 90-95 is what Rick is referring to here.

Thanks. That is exactely what I was looking for.

Does anyone happen to have one and want to part with it?

[Okiyota]

quick correction...

2nd gen Truck is 84-88
3rd gen Truck is 89-95

Just gives you one more model year as an option.

[zukidude1.3]

I noticed you put in a line lock. Stupid question, what for? Guess I cant figure out what you'd use it for. But I'm stupid.

[dirtcheap]

I noticed you put in a line lock. Stupid question, what for? Guess I cant figure out what you'd use it for. But I'm stupid.

my guess would be for an alternative to a handbrake? it was probably easier and less time consuming than installing an e-brake cable on the new back axle...

[zukidude1.3]

my guess would be for an alternative to a handbrake? it was probably easier and less time consuming than installing an e-brake cable on the new back axle...

Makes sense. Thanks!

[GA_ZUKI]

good info

[elotsip]

Hey guys, been away for a while, moved from OR to TX, wife had a baby, bought a new house, trying to get it ready to move in. Then back to work on the sami.

The line lock is there so I can lock up my brakes while on the trail if I need to. I will be installing the cable to the rear brakes as well. But when on steep hill I like to lock the brakes and get the clutch and gas just right, then take off the line lock and start crawling. Sort like you would do with a thumb throttle.

Took the sami to Barnwell Mountain for the 2nd annual Zukikrawler krawl. It performed pretty well but I see somethings I want to change and I still have other stuff I need to get finished up on it.