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Old 07-24-2006, 03:19 PM   #1
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Toyota axle swap

Well, I've finally gotten some time to start this thread going. I am swapping out my suzuki axles for toyota axles, rebuilding them and reinofrcing them as well. I am also going with rear disk brakes, toyoa high steer with an FJ80 steering box. I'll be adding a rear traction bar as well and running toyota drive lines with rock rat adapters.

Started with the rear axle. Here's all the parts that will go into the rear axle


Got the tires pull off the suzuki axle


Couple of ubolts didn't want to come off so I helped them along


Got the rear axle off


Here's what all I removed off the rear


Here's the drive line I will use for the rear axle. It's a front CV drive line from a first gen toyota pickup. As well as the rockrat adapter.


The hardware I received with my adapters was a bit long. Not sure if that is the norm or if I got the wrong hardware. Not a big deal though. I'll just cut the ends of the bolts off.






Here we are setting the drive line angle with teh angle finder. Since it's a CV shaft the pinion will point at the tcase.


Perches are tacked in place


Rear axle is welded up and ready to paint.


I figured I might as well rebuild the axles while I had it all apart. Got the rear bearings pressed out


Here's teh rear axle painted and the shafts with new bearings


I am running monte carlo calipers in the rear. There's a small tab that needs to be ground off on about 50% of the calipers. Its no big deal


Here's the painted axle with the brake lines present


Here's the rear disk brakes




Here it is all together and mounted


With the tires mounted. These are 33x14x15 boggers


Not sticking out too much futher than I was when I was running suzuki axles with 1.5" spacers
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1997 sidekick strut and coil spacers and 31s http://www.zukikrawlers.com/showthread.php?t=41628

Toyota axle swap thread: http://www.zukikrawlers.com/showthread.php?t=2478&

18" Stretch, coils, hydro assist, internal bead locks, etc. http://www.zukikrawlers.com/showthread.php?t=6522

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Old 07-24-2006, 03:31 PM   #2
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Now for the front.

Front axle removed along with steering arms


Sammy with no front axle


This is the third member I am running in the front. It has some rust on the teeth. I was wooried about it but I just cleaned them off as best I could.


Got the lock rite installed


Pulled out the sidekick power steering I was running


These are the brackets that my buddy designed for me. We had another guy burn them out. One plate will be welded to the exisiting toyota perch.


Like this


Toyota front axle with trail gear truss and sky spring perch


Here's teh axle with the lower custom plate


Lots of clearance for the dif to be installed and removed


Here it is with upper bracker attached as well.






I order the knuckle ball gussets from marlin crawler. These things are beefy and fit great!




trail gear diff cap


Custom bracket is spaced in slightly to fit the narrower sazuki spring location.


Here's the fron axle painted and mounted.





We called it quits at this point as it was well over 100 and we had worked Friday evening, all day sat and all morning sunday. Made some pretty good progress. Had to do a lot of running around on Sat to get misc parts that I missed and some toyota only parts as well. All and all not a bad weeked and a good start on the proect.

Future plans are a truss for the rear axle and a new rear traction bar. Still trying to figure out what PS setup to go with up front...
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1997 sidekick strut and coil spacers and 31s http://www.zukikrawlers.com/showthread.php?t=41628

Toyota axle swap thread: http://www.zukikrawlers.com/showthread.php?t=2478&

18" Stretch, coils, hydro assist, internal bead locks, etc. http://www.zukikrawlers.com/showthread.php?t=6522

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Old 07-24-2006, 05:10 PM   #3
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Now, that's what I call progress. Glad to see you're finally getting around to it as I know you've been wanting to do this for a while...

Congrats and keep up the good work!
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Old 07-24-2006, 06:35 PM   #4
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Nice write up!!

Now where are the dirty garrage pics?
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Old 07-24-2006, 09:55 PM   #5
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Very nice man. Those spring plates are trick!

Who did you get the rear axle housing from? I take it you had to get custom rear axle shafts as well.
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Old 07-24-2006, 10:12 PM   #6
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Beautiful! I love how well all your pics are and great design on those pass front plates. I really like those.
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Old 07-24-2006, 10:24 PM   #7
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Your friend should market those spring pads, I'd buy some. Trick!!
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Old 07-24-2006, 11:59 PM   #8
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I removed all the dirty garage pics...

The rear axle housing is an 83 toyota housing with the pumpkin shifted over to line up with the tcase. Sky mfg did the mod. It uses a shortened toyota pickup shaft and a t100/tundra shaft.

My buddy, 4RNRRick onm pirate, is already in talks to sale the plates. It makes the axle swap pretty easy. That was my main concern with the swap.

I order a PSC pump today as well.

Thanks for the comments guys.
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1997 sidekick strut and coil spacers and 31s http://www.zukikrawlers.com/showthread.php?t=41628

Toyota axle swap thread: http://www.zukikrawlers.com/showthread.php?t=2478&

18" Stretch, coils, hydro assist, internal bead locks, etc. http://www.zukikrawlers.com/showthread.php?t=6522

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Old 07-25-2006, 09:03 AM   #9
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I really like the front pass, perch. Looks a hell of a lot better than some designs. sweeeeet
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Old 07-25-2006, 12:30 PM   #10
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I just ordered up some low profile magnetic drain plugs for my toyota axles and Chris at Trail Gear mentioned that will fit the tranny as well. I am going to order a few more for the tranny and tcase.

Here's the part numbers if anyone is interested:
Drain Plugs - Low profile
Toyota Part #'s
90341-18021 Plug w/magnet $1.50-$2.00/ea.
12157-10010 Gasket, diff plug $0.75/ea.
90430-18008 Gasket, tranny/transfer $1.00/ea.
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1997 sidekick strut and coil spacers and 31s http://www.zukikrawlers.com/showthread.php?t=41628

Toyota axle swap thread: http://www.zukikrawlers.com/showthread.php?t=2478&

18" Stretch, coils, hydro assist, internal bead locks, etc. http://www.zukikrawlers.com/showthread.php?t=6522

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Old 07-25-2006, 01:17 PM   #11
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You could alway shave the axles:
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Old 07-25-2006, 01:19 PM   #12
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And the front:
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Old 07-25-2006, 02:35 PM   #13
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I had considered that but the amount of work involved and the time it takes for that extra inch or so of clearance just wasn't appealing at this time. Perhaps once I get it all done I will go back and do that. Right now I just want to get it going again and then start thinking about the next mods. I know a lot of people just do everything all at once but I don't have the time or money so I like to take baby steps.
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1997 sidekick strut and coil spacers and 31s http://www.zukikrawlers.com/showthread.php?t=41628

Toyota axle swap thread: http://www.zukikrawlers.com/showthread.php?t=2478&

18" Stretch, coils, hydro assist, internal bead locks, etc. http://www.zukikrawlers.com/showthread.php?t=6522

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Old 07-25-2006, 04:03 PM   #14
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Just wanted to let everyone know that these prototype plate I'm using will be available through Sky-Manufacturing soon. Not sure on cost.
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1997 sidekick strut and coil spacers and 31s http://www.zukikrawlers.com/showthread.php?t=41628

Toyota axle swap thread: http://www.zukikrawlers.com/showthread.php?t=2478&

18" Stretch, coils, hydro assist, internal bead locks, etc. http://www.zukikrawlers.com/showthread.php?t=6522

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Old 07-27-2006, 03:37 PM   #15
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Well, the local toyota dealer got my parts in today so I can finish up rebuilding the front axle tonight. I'll try to get some more pics posted soon.

After the front axle is rebuilt I will start on the new shock mounts, rear axle truss, new steering setup and figure out what I want to do for the brake system.
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1997 sidekick strut and coil spacers and 31s http://www.zukikrawlers.com/showthread.php?t=41628

Toyota axle swap thread: http://www.zukikrawlers.com/showthread.php?t=2478&

18" Stretch, coils, hydro assist, internal bead locks, etc. http://www.zukikrawlers.com/showthread.php?t=6522

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Old 07-28-2006, 01:05 PM   #16
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Finally got more work done. I was waiting on some parts from toyota to finish up the front axle rebuild.






Rebuilt the hubs while I had them out:


Front axle rebuilt and ready to roll


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



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.....
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1997 sidekick strut and coil spacers and 31s http://www.zukikrawlers.com/showthread.php?t=41628

Toyota axle swap thread: http://www.zukikrawlers.com/showthread.php?t=2478&

18" Stretch, coils, hydro assist, internal bead locks, etc. http://www.zukikrawlers.com/showthread.php?t=6522

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Old 07-28-2006, 03:34 PM   #17
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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!
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1997 sidekick strut and coil spacers and 31s http://www.zukikrawlers.com/showthread.php?t=41628

Toyota axle swap thread: http://www.zukikrawlers.com/showthread.php?t=2478&

18" Stretch, coils, hydro assist, internal bead locks, etc. http://www.zukikrawlers.com/showthread.php?t=6522

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Old 07-28-2006, 05:17 PM   #18
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You Zuk is definitely going to be in the "bad ass" category!!
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Old 07-29-2006, 09:11 PM   #19
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And if you have time after that swap come on down to Cali and you can help me with mine, and yes Ill get the beer and stripers
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Old 07-29-2006, 11:12 PM   #20
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Quote:
Originally Posted by xxlf250
And if you have time after that swap come on down to Cali and you can help me with mine, and yes Ill get the beer and stripers
Now that is trip worth going for!
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Old 07-31-2006, 03:56 PM   #21
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Worked all weekend on the rug again. Made some good progress too.

Got the rear shock locations figured out


Got the front fram cleaned up to mount the steering box and shock mounts


Mock up of the steering box location


Stock FJ80 pitman arm vs. the toyota 2wd 3rd gen pitman arm that I used



box and pitman mounted with plate tacked into place


Back of plating for steering box


steering box mounted up
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1997 sidekick strut and coil spacers and 31s http://www.zukikrawlers.com/showthread.php?t=41628

Toyota axle swap thread: http://www.zukikrawlers.com/showthread.php?t=2478&

18" Stretch, coils, hydro assist, internal bead locks, etc. http://www.zukikrawlers.com/showthread.php?t=6522

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Old 07-31-2006, 04:27 PM   #22
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Well we did some junkyard research today looking for an interchangable Brake master cylinder from the stock 7/8" Bore Samuri Disc/Drum setup to something that has 4 Wheel Disc Brakes, 1" Bore, Metric Fittings, Low level switch and was a bolt-on to the Sami Brake Booster. So what we litteral did was just start walking the wrecking yard looking for cars with rear discs and then lifting the hoods and comparing the master cylinders. Well after tons of lifted hood and on teh second one we pulled to test fit and measure - we found it! Its from a 93' Mazda 929, 3.0L V6, 4 wheel disk brakes with ABS & a 1" bore MC. Plus we got it for $20!

Now before people say to just use the Firebird Master, Its not a direct bolt-in (its close - you have to hog out the mounting holes a touch), doesn't have a low level switch and it has SAE fittings. We wanted to try to find something better before we settled for just what other people have done. Here is a previous post I replied to showing lots of other possiblities: http://www.pirate4x4.com/forum/showthread.php?t=384732

Man do they look identical!





Everything about this bolts-on... but you do have to adjust the plunger in the booster - but thats easy.

Here is what the plunger looks like from the stock sami booster. To remove this from the booster, it just pulls right out.


You then unscrew the end of it and trim off 1/4".


Screw it back on and set it to 2 3/8" long.


Then for a test fit you can double check that to the MC which should be 2 3/4" long from the mounting surface of the Master Cylinder which is what the oringal dimension was with the Sami MC - but I just forgot to take a picture of it.....


And here it is bolted back on.

BTW that black box in the lower left hand corner of the picture, that is plumbed inline with the front brake line is just a electric line lock, which is not required for the swap.
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1997 sidekick strut and coil spacers and 31s http://www.zukikrawlers.com/showthread.php?t=41628

Toyota axle swap thread: http://www.zukikrawlers.com/showthread.php?t=2478&

18" Stretch, coils, hydro assist, internal bead locks, etc. http://www.zukikrawlers.com/showthread.php?t=6522


Last edited by elotsip; 07-31-2006 at 04:47 PM.
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Old 07-31-2006, 04:29 PM   #23
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Got the rear axle truss mocked up


rear traction bar and crossmember.


Rear axle with truss supports and traction bar mounts



traction bar crossmember mounted


everything mounted up.

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1997 sidekick strut and coil spacers and 31s http://www.zukikrawlers.com/showthread.php?t=41628

Toyota axle swap thread: http://www.zukikrawlers.com/showthread.php?t=2478&

18" Stretch, coils, hydro assist, internal bead locks, etc. http://www.zukikrawlers.com/showthread.php?t=6522

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Old 07-31-2006, 04:32 PM   #24
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Here's the front steering shaft. Just mated up the stock samurai shaft on one end the stock FJ80 on the other end and shortened it all


Here it is mounted up
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1997 sidekick strut and coil spacers and 31s http://www.zukikrawlers.com/showthread.php?t=41628

Toyota axle swap thread: http://www.zukikrawlers.com/showthread.php?t=2478&

18" Stretch, coils, hydro assist, internal bead locks, etc. http://www.zukikrawlers.com/showthread.php?t=6522

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Old 07-31-2006, 04:34 PM   #25
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mounted up the front shock towers.



With shocks mounted



Front brake lines installed
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1997 sidekick strut and coil spacers and 31s http://www.zukikrawlers.com/showthread.php?t=41628

Toyota axle swap thread: http://www.zukikrawlers.com/showthread.php?t=2478&

18" Stretch, coils, hydro assist, internal bead locks, etc. http://www.zukikrawlers.com/showthread.php?t=6522

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