Putting the transfer case from the 4Runner in the FJ40 has caused all sorts of issues. I knew this would be the case since the stock FJ40 is passenger side differential and the 4Runner/Tacoma is driver’s side differential. I solved that issue by cutting the front axle pumpkin off, notching the housing for the 3rd member flipping the drain plug from bottom to top; which became the bottom when I flipped the axle, and cutting and flipping the end knuckles. Again this axle issue was solved a long time ago. But that still doesn’t connect everything to provide 4wd.
The front driveshaft needed to have a carrier bearing to work with the leaf spring from axle since the driveline would be flexing. Yesterday I decided to tackle this project. I used a two piece rear Tacoma driveshaft and cut it up to make all the pieces I would need. I’ve gotten half way decent at making new custom length driveshafts. Luckily these are smaller sections, so I can true them and set them up for welding on my 13” South Bend lathe. Using the rear driveshaft for my front driveshaft allowed me to have larger u-joints for strength but it then caused an issue with the small bolt pattern on the pinion flange from the stock FJ40 axle.
My neighbor assisted me on this and made a plate that I could drop the stock flange into and weld. Then I recut the larger profile of the plate and drilled holes to match the new custom driveshaft flange. I could have left the pinion flange alone and used a conversion u-joint but I thought keeping all the same u-joints was a better move. I made a mount for the carrier bearing that comes off of the transmission crossmember. It all turned out well.
I now know that my front section of driveshaft is the correct length (after my initial guess) and now I can fully weld this. One step closer…
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