How To Install a 3rd Gen Off Road OR Axle On a 2nd Gen Tacoma (or non-OR 3rd Gen)

Right. I knew something was off when I was typing that.

 

Some more questions/comments:

why did you leave the old (obsolete??) plugs on the diff behind the shield?

Since you don’t have the 3G 4WD computer governing the locker, you don’t have the <5mph engagement fail safe. You could also find traction control fighting the locker (look into ABS kill switch). If you accidentally hit the locker switch at speed, you will destroy the locker, and quite possibly the diff. This should be your primary concern, especially if others sometimes drive the truck. Leaving the locker on on dry pavement won’t hurt it, but maybe your axles and tires. You could cut the switch’s ground wire and connect to a simple toggle switch (that will arm/disarm the locker switch) to guard against this.

And since your locker switch doubles as indicator, you could super easily (with just one relay) use it to provide ground to the b/y gauge cluster wire and thus illuminate the factory locker dash light

 

Regarding traction control, anyone who has ever installed an ARB or Harrop locker would have the same (hypothetical) problem, but it’s not a problem in practice.

I’ve activated the locker at significantly higher speed than 5mph and my truck didn’t explode. The motion here that matters is the difference in speed between the two rear axle shafts.

If someone is standing on the skinny pedal smoking one rear tire while going nowhere, and also trying to activate the locker, that might be their own damned fault. In that case though, I still don’t think it’s going to hurt anything; it’s just going to prevent the locker from being able to activate.

I left the old plugs where they were because they are part of a wiring harness that includes other components that need to be preserved (aka. the wires for the ABS sensors), and that was just the simplest approach for me.

 

Circling back to this: I am using a prototype harness, which works the way I described on my non-OR truck. But I have since talked to Josh at ExperiMental Designs, who made the harness for me, and it sounds like the harness that actually enters production may, in fact, light the dash light on 2nd Gen OR trucks.

Moreover, he is researching the most efficient way (that is, perhaps without having to get behind the dash cluster) to light the dash light on non-OR trucks.

The locker will still function in 2WD and 4HI as well as 4LO, but he thinks he may be able to illuminate the dash light through the 4WD module on non-OR trucks. There is seemingly no difference in the wiring here, between the OR and non-OR trucks.

There is another reason for this to be preferable, too: if the dash light can be activated, the wiring harness can come furnished with a factory-style switch, which is illuminated any time the headlights are on, instead of only when the locker is activated.

Any input is appreciated, and I will share any updates here as I get them.

 

I currently have a shop trying to install a complete 3rd gen 2018 OR e-locker rear end on my 2wd 2011 OR e-locker truck. Did anyone have any troubles keeping the ABS working? Did that all bolt up or did you need to make something for that? And for the e-locker portion, do i have to buy your wire harness from Experimental biz or will it all be plug n play? Maybe i missed some things in this chat or someone will give me some good answers

 

The ABS is identical between the two generations so is plug-and-play. If you get an ABS light (like I did), it’s probably a bad ABS sensor from the donor axle. So keep your old parts to be able to swap them over if needed.

The locker mechanisms between the two generations are different, so the wiring harness is most likely NOT going to be plug-and-play. Drop Josh at Experimental an email and he can work with you for your situation of doing this on a 2WD truck. On a 2nd gen 4x4’s, the wiring harness plugs into the 4WD module, so he might need to make something custom for you.

Please update us with what you find out!

 

I’ll make sure to give an update! As for the ABS i believe they told me that its bigger on the 3rd gen and may not line up. Anyone have pictures for confirmation?

i have a few updates plus a build process on my insta: blvd_racing in case anyone wanted to check it out. I had a buddy design a big truss on the backside and weld a FGP bashplate underneath for the 3rd gen housing. Regeared to 4.88 by premier west gears who gave us the idea of putting the 3rd gen in, and then all the long travel components to make everything work done by steelnutz. All great guys

 

When I put a 2018 OR 4x4 axle under my 2014 non-OR 4x4, the ABS sensors were exactly the same, if that helps at all.

 

Thank you, I’ll let them know. Funny enough the one i picked up is exactly from a 2018 4x4 aswell

 

The 3rd Gen locking axles are SO much more stout than the 2nd Gen locking axles. The axle shafts are thicker and have more splines, and the ring gears are .75” bigger.

 

Never had a problem with my rear housing and the locker set up. Long story short i got into an accident a couple years ago, the autobody shop (terrible place) wanted to salvage the truck but it turns out there were no problems. I think they snuck in a junk yard rear end because the previous owner didnt recognize it. Anywho, we reached out to premier west gears in order to re gear and build the truss but they recommended that we just pick up a 3rd gen one cause as we all know they are better and stronger. Didnt want to start putting on the long travel system yet but the “junkyard” rear finally caught up to me and started leaking. Literal puddles everywhere i parked it, still drove like brand knew. So now im practically forced to put in this 3rd gen rear because the truck is my daily and might as well upgrade it right. Sell all the parts that come off and hopefully get something back

 

Update: the shop confirmed that the ABS will work perfectly between the two generations. Awesome! I will be reaching out to that ExperiMental Biz you recommended to see if they have a harness (or can make one) for our e-locker application. I’ll let you know when i have more. IDK how to properly post pictures on here but once again, if you are interested in following the build, i’ll have stuff on my insta: https://www.instagram.com/blvd_racing?igsh=NTc4MTIwNjQ2YQ==

 

Belated update:

2nd Gen non-OR trucks do NOT have their gauge cluster locker lamps wired to the 4WD module, so as of right now, we don’t see a good way to light up the gauge cluster lamp that doesn’t involve substantially disassembling the dash, which is more than I want to take on at the moment.

If someone discovers another way, I’d love to know. Does the gauge cluster even have an appropriate wire to tap into, and if so, where might it be found?

Related to this though, I have found several locker switches online that readily work with my harness and can be wired to partially illuminate when the headlights are on, and then fully illuminate when the locker is activated.

(As of right now, the wiring harness only illuminates the switch when I activate the locker. This is the only TRULY plug-and-play configuration; setting up dual stage switch illumination involves splicing a single wire.)

 

Maybe ask that Experimental Biz place. He was actually super honest and quick to respond to me. The 2018 OR housing is installed on the truck as we speak. I talked with him about a harness for the locker but i also mentioned i had an SPODs control panel i plan on installing. He said it’d be a lot easier to just install the control panel and power it through that than to make a custom harness. I wonder if it can be made to illuminate the dash still or maybe its redundant since the switch panel will tell you anyways. I actually found out that company are the ones who originally made the “anytime locker” but had to switch the name to “freedom locker”. Pretty good work. As for non-OR tacos and the dash, correct me if im wrong, but i would figure all dashes to be the same? They should have spots for all the lights including locker and 4x4 with empty spots to plug into. I know of a couple guys who have done the FJcruiser manual transfer case install and they got the 4x4 (on a non 4x4 truck) to light up. If that worked for them perhaps the locker light is also there and can be made to work aswell

 

Yes, I have been working with Josh at Experimental. He’s the one who discovered the gauge cluster locker lamp is not connected to the 4WD module.

We know it has the lamp. We just don’t know where we might find the right wire to light it without disassembling lots of stuff to get behind the gauge cluster.

 

Gotcha

 

Hey 1st timer/lurcher, ... Doing the same mod with my 08 sport. Thanks for the write up and pics!!
Just got my front and rear 3rd gen 4.30 w e-locker for the swap. All in, still cheaper then regearing and locker rear. Plus the added bigger diff would be better for my alucab set up.
Talked to Josh and waiting for the harness to be done up. I do have an 06 OR as donor with locker. I might try to swap the ecu to see if it will light up the dash. But I am also doing the fj t.c. swap at same time. Just trying to figure out how to do the front axle...ADD delete or just an harness like the rear...
I'll keep updates when the install goes through...

Cheers!

 

An 06 OR as donor with locker?? 2nd gen diff components are incompatible with 3rd gen diff components, and v. Versa. The gears are different sizes (not just a difference in ratios) and the locker mechanisms are integral to the housings and are not individually swappable. For starters, 3rd gen diffs are bigger and have 32 spline outputs instead of 30 spline.

2nd gen OR axle assemblies are also weaker than 2nd Gen Sport axle assemblies. I found this out the hard way, as I also have a camper on my truck and drive it off road. I started by swapping in a 2nd Gen OR axle assembly to my TRD Sport and broke the ring and pinion gears with a small axle hop on a climb that was 30 degrees or less.

As far as this particular thread is concerned, you need to start with a complete 3rd Gen OR axle assembly that has the locker already built in.

As for the 3rd Gen front diff, it is exactly the same as the 2nd Gen front diff except for the gear ratios. No additional wiring harness is needed unless you want to also add a front locker, which will come with the appropriate harness.

 

Sorry, my french got the best of me.... I do have the full front and back axles from 3rd gen 4.30 with e lockers sitting on the garage floor going under my 08 (camper)... The 06 OR donor taco was a project until the motor crapped out. Now it's a parts/spares truck. I got the truck dirt cheap.
Went the 3rd gen route after seeing your post. Way less complicated then swapping gears and adding e locker and less expensive! Just need to find a t.c. The one I just got yesterday is junk and going back for refund.

 

As a general update to this thread: The wiring harness I used plugs into the 4wd module as a simple way to draw power — nothing else.

If you have a Switch-Pro (e.g), or are comfortable with otherwise supplying power to the rear locker via a relay and a switch, there is no reason to use the harness I described. Since performing this swap, I have since met another 2nd Gen owner who also swapped in a 3rd Gen axle assembly and (had a shop) wire it directly to his switch pro.