View Full Version : Knuckle Rebuild on FJ60

05-29-2011, 01:36 AM
So this isn't exactly a 4 Wheeling run or even a Rising Sun event, but I will be rebuilding the knuckles on our new-to-us FJ60 tomorrow, Sunday May 29. If anybody wants to drop in to :lmao: or get greasy or anything in between, there will be pizza and refreshments.

Address and phone are in the roster - or pick up an issue of Toyota Trails from 2003-2010.

Happy cruisin'!

05-29-2011, 07:56 AM
I'll change my fishing destination from Deckers to Bear Creek. Seems like the makings for a great day; some fishing, some wrenching. See you later (mid to late) this morning. :D

06-02-2011, 03:50 PM
I didn't want to add to this thread until Kraig moved it over here to tech for me - thanks Kraig!

Huge thanks to Ricardo for coming over and helping me spin wrenches on Saturday. Teardown was pretty straightfoward, and we encountered no major difficulties.

The main reason for doing this was baselining the rig since I just got it, and it was clear at least one of the axle seals was shot from the goop getting past the wiper. Also, the brakes were pulsating, so at a minimum the rotors were going to need to be turned. I went ahead and got new OEM rotors and pad from Stevinson. Just my luck if I hadn't done that, I would have taken the rotors in and they would have said there wasn't enough meat to machine them.

Here is a picture of Ricardo working on getting one knuckle off.

06-02-2011, 03:54 PM
It turned out that both sides had bad seals, but one side was worse than the other. It was a good thing we went in there - one knuckle bearing literally fell apart when Ricardo removed it, and there was only a smidge of actual grease in either side. The rest was Frank's backwoods goop :D

This picture is just some miscellaneous parts after cleaning.

06-02-2011, 03:56 PM
In this picture, Ricardo is tapping out the outer knuckle bearing race.

06-02-2011, 03:58 PM
The birfs were both in real nice shape, and thank goodness the seal surfaces weren't grooved.

06-02-2011, 04:00 PM
After Ricardo left I started putting things back together. The knuckle kit came with hub dust seals, a nice touch.

06-02-2011, 04:07 PM
The only real "uh-oh" came when I took the new rotors out of the boxes. The old rotors are held onto the hubs by a pair of M10 bolts plus the 6 wheel studs. The new rotors didn't have threaded holes for the bolts. Don't you just hate it when you finish a job and there are leftover bolts?

I checked my fast moving parts catalog (http://rzeppa.org/tech/fast.htm) and the Toyota part numbers on the new rotors were not listed anywhere in there.

I stopped and had a :beer: and scratched my head. It was way too late by then to call Stevinson and verify that they sold me the right rotors. But everything else about them seemed to fit. So I :dunno: shrugged my shoulders and chalked it up to Toyota constantly morphing their parts.

06-02-2011, 04:11 PM
Lookin' good. There were a couple of instances where things were much improved over what I found in there. First of all, the knuckle stud split washers clearly were not OEM. They were thinner and completely flattened, rendering them useless as lock washers. I replaced them with OEM. Likewise with the hub lock washers (note to self - gotta call Stevinson and replenish my stash of new OEM fasteners to have on hand!). The rig had these silly chrome covers for the hubs, and they had rusted the hubs pretty good by retaining moisture. So after I got all the loose rust off with a wire wheel, Ricardo painted them with some black enamel I had laying around.

06-02-2011, 04:17 PM
I did have one issue where the groove where you put the grease seal on the hub over the inner wheel bearing was buggered. I wasted 2 seals trying to get them in there straight. At that point I called it a night. The next day, after thinking about it a little, I just ground the surface flat really carefully and then came back with some 400 grit sandpaper and smoothed it down really nice and then the seal went in perfect.

I had another issue with the cheap star washers that came with the kit. I was tightening the locking nut and when I re-checked the preload with the fish scale it had increased??? How could that be. Took it apart again, redid the adjusting nut then once again the darn thing tightened up on me when I tightened the locking nut. Then I noticed that the little nibbie (tech term) on the inside of the star washer was sheared off allowing it to spin. :homer: D'oh!

So I reused the one that was in there. I probably had another spare somewhere but I didn't feel like looking for it.

06-02-2011, 04:20 PM
Are you going to use the Warn hubs or switch back to some Aisin ones?

06-02-2011, 04:24 PM
This is probably the only 60 I have ever seen with Warn hubs. But they are the premiums at least. They seem a lot more stout than the Warns on my 40s.

When we first took them apart, I thought it was like when you see a 76-78 with a mini truck birf and they had used fender washers and bolts instead of the circlip. But wait a minute??? This is a 60 and it is supposed to have the short birfs. Then I realized that they made this warn hub so it would fit both long and short birfs. If you got long birfs, use the circlip, if you got short ones, use the washer and bolt.

06-02-2011, 04:26 PM
Just out of curiosity I measured how thick the brand-new pads were. Then I measured the groove - exactly 8mm deep. Turns out it is precisely at the wear limit listed in the manual.

06-02-2011, 04:28 PM
After buttoning everything up I went out and bedded in the brakes. No more pulsing, and they stop really well. This rig also has exceptional rear brakes, and a parking brake that works too!

I got some idle issues ever since smog, but I'll put that up in a separate thread.

06-02-2011, 04:30 PM
Are you going to use the Warn hubs or switch back to some Aisin ones?

I've never had any problems with Warn hubs. I have them on 3 out of 4 cruisers. These seemed nicer than the ones on my 40s.

06-02-2011, 04:54 PM
Great writeup and photos, Jeff - thanks!