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DomOfTheDead's 1996 FZJ80 build

DomOfTheDead

Event Coordinator
Cruise Moab Committee
Joined
Jun 2, 2019
Messages
898
Location
lakewood
This thread is to chronicle the build up of my, new to me, 1996 FJ80 land cruiser. The decision to go with an 80 series was influenced by other 4x4 build ups I had done in the past and, primarily, by some of the excellent 80s within Rising Sun. From beautiful stockers to baja proven trucks to hard core trail rigs, the solid axles and coil suspension make for an excellent base to start with.

My intentions are for a mostly hard usage trail truck. Minimal lift, 35-37" tires, lockers and low gears in axles and tcase. I want to keep center of gravity as low as possible and have lots of low gearing.

In an attempt to keep this fairly low budget, I was searching for a late model 80 (for the full float rear axle and obd2). In early January, with help from @DanielChase , I acquired a 1996. Sadly, the truck didn't come sporting lockers, blower or much anything other than 260k miles and some chrome crap but for the money, it still fit the plan. According to carfax, i am 3rd owner of a Stevinson sold truck that lead a quiet life in Colorado for most of it's life until ending up in a few different auction yards to spend 2 years in the sun and slowly dry rotting. We found it sitting in a dirt lot, with a dead battery, tires cracked and half deflated, wasted brakes and clicking birfields. But, it ran ok and tcase was functional so we limped it home.
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first night: installed a new battery and ordered some hood struts
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The next day
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in waiting for my brake and axle rebuild parts to arrive, i spent some time doing simple stuff while the weather was nice: new driver side mirror, sound deadened doors and new speakers, center console covering
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oem cd / tape player wouldn't work so in went an Alpine deck
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I plan to remove the plastic pocket to install a cb unit under the Alpine in the future. And fill that sad spot where the center diff lock button should go.

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the #2 cat was cheap and easy so it was replaced. Old unit looked ok in after analysis but it is done now.

Who doesn't love broken bolts?
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pulled off the running boards, some of the chrome and installed my 305 Coopers on method pseudo locks. The oe rims had to be hammered off of the hubs with sledge and wood blocks. Not a fun way to just see how it sat on the wheel/tire combo but had to happen. The oe wheels are nasty (except the spare) and need sand blasting.
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tire clearance is already pretty good except for some fender trimmings. Also dumping this awful push bar ASAP.
 

Notyourmomslx450

Cruise Moab Committee
Cruise Moab Committee
Joined
Aug 4, 2014
Messages
3,253
Location
Westminster
Off and running!
I love my gear reduction in the case (5.29's in diffs), but coming from mini trucks I definitely wish I could get lower.
Ether way you're going to love it!
 

DomOfTheDead

Event Coordinator
Cruise Moab Committee
Joined
Jun 2, 2019
Messages
898
Location
lakewood
Axles and brakes

As a side note, I have only book learned knowledge of toyota axles previously. Not much hands on experience. My Former build ups were all General Motors and subsequently, axles were GM 8.5" 10 bolts front/ rear and later, Dana 44 front and GM 10.5 full float rear. If I make comparison, it is to these designs. You can kinda see the 44 in this pic😉
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To drive the 80 safely to emissions testing, brakes needed to be replaced. Bearings are integral with hubs. And the birfields click when turning...so rear axle first.
20210206_132759.jpg

the end goal involves differential rebuild in addition to brakes and bearings but due to current budget limits, I am leaving the third members alone for now in interest of just trying to get it running, legal and wheeling.

I hear this is common with these studs.
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how about these little nightmares? I have only previously dealt with cone washers on steering components not miniature ones at the ends of the axles. How diabolical! Until you learn the art of removing them that is. But that lesson I learned later. At this point, they kicked my ass and it took 90 mins to remove the 12 from the rear axle shafts using mini sledge, brass drift, wd-40 and a propane torch.
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remove and install new bearings and seals, brake hoses, calipers, brackets, rotors, pads, reassembly of rear components.
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yeah yeah I know powerstop sucks. It was a cost and availability issue at the time so I will deal with it if problems arise.
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In hindsight, I should have painted the hub and shaft.

On to the front axle...
 

Lastresort576

Hard Core 4+
Joined
Mar 21, 2016
Messages
588
Location
Westminster
Wait power stops suck? Lol I only read good things about them on mud today. Maybe those posts were dated.

looks like an awesome start to a great build!
 

DomOfTheDead

Event Coordinator
Cruise Moab Committee
Joined
Jun 2, 2019
Messages
898
Location
lakewood
Wait power stops suck? Lol I only read good things about them on mud today. Maybe those posts were dated.

looks like an awesome start to a great build!
Opinions vary, right? I put powerstop rotors and drums on my Tacoma with only a minute difference but it seems like having slotted/drilled rotors couldn't hurt either. That's part of why I bought them again, that, price and convenience. I know that drilled rotors can crack if too close to an edge of the rotor but I am not too worried about that happening. IMO the biggest issue with the powerstops is the pad break-in demands.
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J1000

Rising Sun Member
Joined
Oct 11, 2018
Messages
1,565
Location
Morrison, CO
I have Powerstop on my truck and have no complaints. They are quiet, low dust, and have massive stopping power. I was towing back from SLC the other week and an elk stepped out in front of me and I hauled on the brakes as hard as I could and I dodged that elk by the skin of my teeth. So yeah I'll buy Powerstop again.
 

Lastresort576

Hard Core 4+
Joined
Mar 21, 2016
Messages
588
Location
Westminster
I have Powerstop on my truck and have no complaints. They are quiet, low dust, and have massive stopping power. I was towing back from SLC the other week and an elk stepped out in front of me and I hauled on the brakes as hard as I could and I dodged that elk by the skin of my teeth. So yeah I'll buy Powerstop again.
Good to know, and glad you saved it.. By chance are you running those rotors on your ep3(thats if you still have it)
 

DomOfTheDead

Event Coordinator
Cruise Moab Committee
Joined
Jun 2, 2019
Messages
898
Location
lakewood
FRONT AXLE (part of it)

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it's payback time! thanks to @Stuckinthe80s for advice on using an air hammer to remove the cone washers. The only issue was my compressor is loaned out so i had to improvise. Looks pretty cheesy but it worked. All front 12 washers out in less that 2 mins.
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here what i found when i pulled the passenger side flange, snap ring MIA, both axle nuts and washer completely off of the spindle threads. Glad i didn't drive around more like this.
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this is the spring for the hub seal.
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the driver side was in better shape but the axle nuts were beat up like someone tried to service the front axle hubs but did a crappy job. I pulled the knuckles and birfields out and...
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i think the Nietzsche quote goes "if you gaze into the chocolate axle pudding long enough, the chocolate axle pudding will gaze into you" or something like that. Looks like the axle seals failed
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where have you been all my life, parts washer? You're my new favorite thing in this world
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one knuckle had a broke steering stud. It drilled out fairly easily and was replaced
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cleaned and painted the knuckles, new axle seals and kingpin(? I know it isn't a kingpin but calling it that for now) bearings, shims, knuckle wipers and associated parts, brake hoses replaced.
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and this is how it sits as of today, waiting for new birfields. I decided to order from RCV last week because of their warranty and quality but they are 3 weeks out. I was hopeful to bring the 80 to Cruise Moab but the truck needs some more tlc (finish reassembly of the front axle, bleed brakes, tie rods, trans and coolant flush, emissions test and plates, alternator brushes, starter) before it is road ready and trail worthy. Looks like mid may at this point for the maiden voyage. Thanks to everyone for their support and feedback!

Rising sun rocks!
 

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damon

Vice Commander
Cruise Moab Committee
Joined
Nov 28, 2018
Messages
1,127
Location
Arvada, CO
Wait power stops suck? Lol I only read good things about them on mud today. Maybe those posts were dated.

looks like an awesome start to a great build!
I have Powerstop rotors in the front, and previously had their pads. They work decently once they warm up, but when they were cold they were dangerously weak. I swapped out to OEM 100-series pads, and the difference is night and day.
 

Danger Noodle

Trail Ready
Joined
Oct 5, 2020
Messages
437
Location
Divide, Colorado
FRONT AXLE (part of it)

View attachment 94098it's payback time! thanks to @Stuckinthe80s for advice on using an air hammer to remove the cone washers. The only issue was my compressor is loaned out so i had to improvise. Looks pretty cheesy but it worked. All front 12 washers out in less that 2 mins. View attachment 94099View attachment 94100here what i found when i pulled the passenger side flange, snap ring MIA, both axle nuts and washer completely off of the spindle threads. Glad i didn't drive around more like this.View attachment 94101this is the spring for the hub seal.View attachment 94105the driver side was in better shape but the axle nuts were beat up like someone tried to service the front axle hubs but did a crappy job. I pulled the knuckles and birfields out and...View attachment 94104i think the Nietzsche quote goes "if you gaze into the chocolate axle pudding long enough, the chocolate axle pudding will gaze into you" or something like that. Looks like the axle seals failedView attachment 94106where have you been all my life, parts washer? You're my new favorite thing in this worldView attachment 94107one knuckle had a broke steering stud. It drilled out fairly easily and was replacedView attachment 94108View attachment 94109View attachment 94110cleaned and painted the knuckles, new axle seals and kingpin(? I know it isn't a kingpin but calling it that for now) bearings, shims, knuckle wipers and associated parts, brake hoses replaced. View attachment 94111and this is how it sits as of today, waiting for new birfields. I decided to order from RCV last week because of their warranty and quality but they are 3 weeks out. I was hopeful to bring the 80 to Cruise Moab but the truck needs some more tlc (finish reassembly of the front axle, bleed brakes, tie rods, trans and coolant flush, emissions test and plates, alternator brushes, starter) before it is road ready and trail worthy. Looks like mid may at this point for the maiden voyage. Thanks to everyone for their support and feedback!

Rising sun rocks!

Reminds me of my front axle. Mine was a bit chunkier though.

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It's astounding what POs will do.

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You think you are going to make it for Cruise Moab?

-DJ
 

DomOfTheDead

Event Coordinator
Cruise Moab Committee
Joined
Jun 2, 2019
Messages
898
Location
lakewood

DomOfTheDead

Event Coordinator
Cruise Moab Committee
Joined
Jun 2, 2019
Messages
898
Location
lakewood
Reassembly of the front axle outers.
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new brakes, calipers, hoses, bearings, seals, tie rods. Due to time and budget constraints, I decided to reinstall the stock birfields and reallocate funds. I will order RCvs at another time. The the oe drag link was in bad shape so in went slee steering links.
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can of degreaser on the front end and new steering stabilizer that bent the mount already😡
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passed emissions test😄
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and then the front sway bar fell off
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ready for action
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Notyourmomslx450

Cruise Moab Committee
Cruise Moab Committee
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Aug 4, 2014
Messages
3,253
Location
Westminster
I like those wheels!
I've been thinking about getting new wheels for my 80.....
 

DomOfTheDead

Event Coordinator
Cruise Moab Committee
Joined
Jun 2, 2019
Messages
898
Location
lakewood
I like those wheels!
I've been thinking about getting new wheels for my 80.....
They are method pseudo locks. My oe 80 wheels are nasty and unfit for reuse at this time (needs to be sand blasted). I bought the methods for the taco and plan to reinstall them on it some day but for now they worked out wheel/tire wise better for the 80.
 

bassguyry

Commander + Cruise Moab Chairman
Staff member
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Jun 14, 2018
Messages
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Arvada, CO
That thing is looking sweet, Dom!
 

MonPetiteShoe

Cruise Moab Committee
Cruise Moab Committee
Joined
Oct 7, 2020
Messages
442
Location
Aurora
Your front axle PO problems sound like mine, except in reverse. I ended up replacing the driver's side spindle because the threads were stripped smooth for a 1/4 inch. Lock washer was installed, but was never bent. I had initially diagnosed the driver side wheel play as bad trunnion and wheel bearings...
80's lookin' good, lemme know if you want an extra hand with anything.
 
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DomOfTheDead

Event Coordinator
Cruise Moab Committee
Joined
Jun 2, 2019
Messages
898
Location
lakewood
Finally plates! And the most pleasant trip to the lakewood dmv I have ever experienced. Appointment setup online and out of there in 20 mins.
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this made me so happy I decided to flush the coolant! (Not pictured)

A friend gave me this alarm system a while ago so I put it on the truck
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