Budget Solid Axle 2nd Gen

Just joined. Almost done with this build, but needing some input from the experts. Never really messed with Toyota’s.

Started this build a few months back. I’ll get everybody up to speed slowly as I have time to post.

It had a good start when I got it.
Had a ECGS rear 60 with a grizzly locker and 35 spline chromos.
FJ case swap was done (console was a little hacked up)
Chevy 63in springs in rear
Front diff was removed.
Had total chaos LCA’s and some aftermarket uppers. (Sold them on FB)

front crossmember was already modified for a winch.

this is how I got it.

 

It also had a flatbed on it and a fuel cell. Really frees up space under the frame.

That first gen is my buddy’s. We had just finished up his 3 link front and were getting started on my budget SAS.



Got to work with removing all the IFS stuff.

 

I knew how much work went into my buddy’s 3 link so I decided to go back 30 years in suspension technology and run leafs.

I had a couple 1990’s Ford Dana 60 fronts laying around so I decided to use one of them.

I settled on a set of stock ‘02 tacoma rears I had laying around and decided to use slider boxes up front.
Had to add a few misc leafs to the packs to get the height I wanted.

Spring perches are wider than Tacoma frames up front so I had to outboard the front mounts. Turned out okay.

 

Following along. Always liked the idea of a simple, leaf sprung sas on our trucks.

 

Nice start! You looking to sell those LCAs??

 

It always starts simple! It gets a little more interesting.

 

I already sold them. That’s how I funded the rest of the build. Sorry man

 

Got the axle cleaned up. Had a buddy bring it down from NY a while back. It was a little pitted.



Welded the tubes to the housing.

 

Got it on its own weight. Still a long ways to go!



Rear end had 4.56 gears, so I matched them up front.
Pattern turned out okay.
Had a Detroit sitting around. Threw that in for a locker.

all new seals, etc into the axle.

 

Steering box is next. Had to trim out part of the fender and remove the radiator to get in there right.



Ordered a flat pitman arm, but the drag link still hung down too far.

Had to cut it in half and flip it to mount the DLE on top.

 

Frame had to be cut ALOT to clear everything.
Plated it inside and out.




Extended a steering shaft I found at the junk yard to work.
Got an adapter U joint thingy to weld on the end of the 3/4in solid bar to go to the steering column shaft.

 

Made a drag link and tie rod too...

So Toyota IFS boxes have about 6-7 inches of throw depending on your pitman arm. The high steer arm I used was made for 8 inches of throw. I had to use the hole that is closer to the knuckle. This moved my drag link back closer to the motor at full lock to both sides.
This meant I had the axle about 1/2in too far back.
Drag link was getting into the lower idler pulley.
Notched it out and made some funky bends. Seems to clear.

 

Frame still flexed more than I wanted.
Added some more bracing and cleaned up my plate job.



Also ordered some frame plates from WFO. Fit great. Just tacked them as I went then welded them in. Modified drivers side to fit around what I had already plated.

 

Painted some things. Tried to color match it.

 

35 spline outer shafts. Spicer U-joints. Stock 35 spline inner shafts.



axle bolted underneath.

 

Drilled and tapped the steering box. threw some paint on it as well.

 

Decided to run a Surplus Center 1.5x8in ram for hydro assist. Running the stock pump for now. Not sure if there are any other options for one with more PSI that will bolt in.

Ram mounted and lines run.

used a 1981 TOYODA steering reservoir. Cut it, rolled some tube up and TIG’ed it up.
Hopefully there is enough volume so the pump does not starve.

 

Im in

 

Time for a front driveshaft.
Had a long slip double cardan shaft I had cut down and retubed with .25 wall tube.
Had to get a flange for the 60. Trail Gear came through.

Cut out the stock crossmember.
Modified it to clear the droop of the driveshaft.

 

Clean fab work. I have done a bunch of SASes on ifs rigs and the only thing I would have done different would be that I would have hung that steering box way farther out. To make room for the box, hacked up the rad support, cut off the body mount and fabbed a new one around the steering box. Then pushed the axle 6” forward and had crazy good approach angles. BUT not being there and personally seeing what you where building with, my opinion is essentially worthless.