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Page 2 - Toyota 80 Series Electric Locking Differentials Retrofit for an FJ60

Well, I guess I’ll start with a list of parts you’ll need.

  Front:

  - Complete 80 series REAR locking differential (aka complete 3rd member or drop out 3rd).  This can be had new or used.  New is around $1000 (with the actuator included) from the dealer.  I found mine used out of wrecked 80s by using the search on Car-part.com and neither one of  mine were even $500 and both were in excellent condition and worked perfectly.

- Long-splined, long-side (aka drivers side for US) inner axle shaft.  This can be either an OEM part, or a custom made shaft.  I found a used OEM shaft from a Cruiserhead on the LCML.  Finding a used one will be hard, and trying to get a US dealer to order you one will probably be even harder.  A custom one might be easier to find.  You'll find a list of some places to try at the end of the write-up and a list of OEM Toyota part numbers as well.. (Long-spline photos courtesy of Dave Tay.)

- Longer diff studs.  You need a total of 6 longer diff studs (you may be able to get by with just 4 new ones, but I recommend just replacing all 6).  The red ones are ~91 mm long and the blue ones are ~53 mm (part numbers).  The other 4 (not circled) remain stock length.  (Side note:   The stock 80 series diff stud configuration is a bit different and includes like two other sizes.  I chose to do it this way 'cause it works and is easier to deal with because there is only two new sizes.)

You also need a new diff gasket.  I like to use the stock Toyota gasket.  You can use either the stock FJ60 gasket or the stock FZJ80 diff gasket--but that will mostly depend on whether or not you grind the diff housing which will be talked about later (part numbers).

Also, if you haven't replaced your bearings and seals recently, do it at the same time--you're going to be in there anyways.  One thing to note on the axle seals:  if you purchase a new OEM Toyota shaft, you must also purchase a new corresponding OEM axle seal (the sealing surface of the newer axle shafts went from 34 to 35 mm and thus need the corresponding newer seal.  You would of course still use the older seal size for the older stock axles (part numbers).

For front axle rebuild info see Morgan Fletcher's Axle Overhaul write-up on Birfield.com.  Follow along there if you are going to replace seals and bearings.  Otherwise, to get to the install info, click next.

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