[zookernator]

Well heres my 2 bobs worth of input from when i did the conversion about 12 months ago. The conversion was for a 1991 WT sierra. I used the front housing from a flat tray 1980 lux.. and a bundera using for the rear (not sure of the date). At first, i tried using a standard hilux rear, but due to the transfer being off centre, i had HEAPS of dramas, which is why i went to the bundy housing. I also put hilux front springs into the rear of the zook at the same time. I ordered new perches, high steer kit, shock hoops, shock mounts, U bolt flip kit, and the kit that aligns the drivers side perch to the correct location (cant really use a new perch in the correct location cause the diff centre is in the way). All the parts are here.. http://www.lowrangeoffroad.com/samyotaswap.htm

Next, i started on the rear.. pulled out the zook diff etc..


Then i welded the new perches on in the right spot, i also welded new shocky mounts onto the housing, and inverted the shocks. With the utilising the 3 hole perch, i also moved the diff back 1".
The lux diff in the rear, with the original zook front still


Then i started on the front. I ripped out the housing etc, took off the old shock mounts, and steering (tie rod etc, but left the sierra steering box)
Then i made up the high steer kit, and bolted it on, and made up the other kit to re-align the drivers side perch




Here she is "nearly" all done.. a flexy pic. This is with 32's, and was 5" wider than the original zook diffs


At this stage, i also made up the shocky hoops etc.




On the first test drive, i started having HUGE probs with bad vibrations.. i tried making up castor wedges to get the diff and transfer flanges paralel


Didnt help at all. I also tried running double cardon joint shafts etc.. didnt help either. Oh, i'm also using a hilux rear shaft in the front.. just chopped down to suit.

In this pic, you obviously cant see the difference in the flange angles.. but ya can "sort of" see the other 2 angles. no wonder the poor uni's were vibrating like mad


then i found a bundera diff.. which is off centre Luckily i still had some spring perchs and shocky mounts left over.. so i chucked them in for the photo to!!


Cleaning them up ready..




Here she is all pretty much back together. Oh, for memory i welded the perchs on so the 2 flanges were 0.8 degrees different.



First test drive, problem fixed!! Drove beautiful! (oh, now im using a lux rear shaft in the rear aswell.. so no more DC shaft!)


Now im running 35X11.5X15 tires.. and this is the track width (on cruiser rims)



Then i did a RUF, and with the SPOA the brake hoses were to short.. so i made up new mounts




The new setup.. with new brake hoses too.




A good shot of the high steer and diff etc..


Oh, i also Had some more dramas with uni angles.. the standard lux uni was crashing on itself and wasnt allowing flex.. after a bit of researching.. i found a slip joint out of a 85 lux (DC joint end) has heaps more angle!!
.

At the end of it, i am running these 35's.. twin lockers with a vitara EFI motor, and havent busted a single thing. Hope i havent missed anything.. please add anything else anyone can think of! Im sure the list will be huge! hehe

[unique_seek]

awsome stuff mate!!!i got a coily

[Saam]

so what ? that means when you go lux diffs your go coils...

[unique_seek]

more mods to make them suit coily?

[keechox]

hey coxy, good write up..... what was the story at agfest? 2wd? or was it just to easy?

[keechox]

hey coxy, good write up..... what was the story at agfest? 2wd? or was it just to easy?

[eldo]

excellent write up

[zookernator]

keechox wrote:

hey coxy, good write up..... what was the story at agfest? 2wd? or was it just to easy?

hehe, just having fun in 2wd matey!!

[zooktastic]

was there any difference in width between bundera rear diff and hilux? i have heard 2 different storys from verious people, how does the bundera diff go coping wiht 35s?

[Dol_190]

Hey mate i just ordered all the gear from lowrange to do this conversion...
i have standard diffs out of a 84 hilux also, a hilux transfer on a T700 auto which is already fitted,
any pointers would be much appreciated
Excellent write up by the way

[Locks]

Has anyone done the hilux diffs conversion and not had a bad vibration through the back tail shaft?

Is it worth doing this and staying SUA to keep the CG down low?

[zookernator]

Locks wrote:

Has anyone done the hilux diffs conversion and not had a bad vibration through the back tail shaft?

Is it worth doing this and staying SUA to keep the CG down low?

Using a bundera diff will housing result in no vibrations at all, and it is the exact same process as fitting up a hilux diff housing.