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-   -   FJ60 Front Axle Knuckle Rebuild (http://www.risingsun4x4club.org/forum2/showthread.php?t=20479)

Opie 11-10-2013 11:51 AM

FJ60 Front Axle Knuckle Rebuild
Hi Everyone,

My name is Opie. I'm new to Rising Sun and look forward to attending a meeting.

I just acquired a '86 FJ60. It hasn't been driven much recently due to leaking axle seals. It probably also has a bunch of other stuff wrong, but that's the first priority as grease is getting on the brake rotors.

From what I've read, it doesn't look like a hard job (albeit messy) but currently, I don't a place to work on it. I live in a condo complex in Boulder. With weather rapidly getting colder, doing this outside doesn't sound like much fun either. It's not my daily driver, so it can wait, but I don't want to let the truck sit much longer less it become a basket case.

I contacted two vendors to see what they might charge and I'm waiting to hear back on quotes. In the meantime, I thought I'd reach out to the community and see if one of you are interested in tackling the job as a side project. You know, make a little extra cash before the holidays kind of thing.

If you've done this before it's probably a fast/easy job for you but it could be a eat up a whole weekend for me. Of course, if the price is un-affordable I might end up doing it myself.

Here's the procedure:

It looks like I can get the rebuild kit for $92 from Cruiser Outfitters.
Part #FA7590

Here's my new FJ


Thanks for the responses!

nattybumppo 11-10-2013 02:50 PM

I can recommend the kit from Cruiser Outfitters, but add the Marlin seals (you need two at about $8 each) to use instead of the stock ones in the kit. You also have to add for wheel bearings if you choose to replace them, but depending on how many miles are on your truck, you may not need to. I have done this job twice and it still takes me about a day each side...of course I'm notoriously slow and easily distracted by kids needing attention and such. It is not a hard job, but quite messy. You should do it yourself if you can figure out a good place to work. It is very smart to get in touch with your front end so you are in the know in case you run into problems on the trail with a birf or something.

RicardoJM 11-10-2013 03:26 PM

I agree with Nattybumpo, get the parts and get it done. I have done the full service on my rig and helped a few others with the job over the years. If you do decide to do the work, let me know if you need a hand.

Opie 11-10-2013 03:55 PM

Thanks, guys. I'll let you know how it goes!

nattybumppo 11-10-2013 11:34 PM

OK, here's four tips. 1) make sure you have and use your FSM, 2) tap the cone washers with a brass hammer to loosen them up for easy removal after you take out the bolts, 3) use care to seat those Marlin seals square and snug, and 4) insert your long side axle shaft first, then you can juggle and slightly turn either side axle shaft as necessary to get the teeth to line up so you can get the short side shaft fully inserted...Ricardo is the master at this, and it is a little tricky. Oh yeah...5) make sure you are careful not to damage the metal shims on the top and bottom knuckles as you take it apart. You want to make sure you can re-use them so you don't have to go through the complex measurement process during reassembly (I believe this is what sets your caster so keep the shims wioth the appropriate parts).

Inukshuk 11-11-2013 12:37 AM

I disagree about Marlin Seals. My experience was they wore groves in my inner axles much faster than OEM.

MDH33 11-11-2013 07:33 AM

Hi Opie, nice 60.

All good advice so far. Although I don't have any long term experience with the marlin seals.

I would recommend doing the bearings while you're in there.

There are some specific tools and supplies you'll need to make this job easy: factory service manual, parts washer, brass drifts, 54 mm socket, luggage or fish scale, lots of towels and brake cleaner, molybdenum grease for the birf, regular wheel bearing grease for the bearings.

If you buy the supplies and decide you don't want to jump in, pm me. I'm laid off right now and can do it for a lot less than a shop. Ive done it on 40's, 60's, minis,etc.

Inukshuk 11-11-2013 10:36 AM


Originally Posted by MDH33 (Post 241950)
I'm laid off right now and can do it for a lot less than a shop. Ive done it on 40's, 60's, minis,etc.


CardinalFJ60 11-11-2013 10:37 AM

quick hi-jack.
Hey Martin!

I need to do the 40...but have never done it myself. I'd love to take you up on that offer and maybe we do it together...And still help ya' out while between gigs. I reeeaaallly need to know how to do this, but would want some guidance on the first go-'round. I don't have a parts washer...but most other things. I'll move this to PM in the event we can get together someday (my place or yours). I do have a heated garage space. :thumb:


MDH33 11-11-2013 12:12 PM

PM'd you Shawn. :thumb:

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