The Warn Black Diamond Suspension was modified to function properly on the FJ-40 and does a great job of handling the trails. An AGR Rock Ram was installed to assist in navigating the hefty meats. The rig also uses disc brakes at each wheel. | 
The Warn Black Diamond suspension system allows Donald's FJ to crawl freely, unrestrained by suspension limitations. The skidplate was cut out so rock lights can guide the way during night runs. | 
The rear Dana 60 was built by Don's 4x4 using 4.88 gears and an ARB Air Locker. The Warn suspension took quite a bit of massaging to fit it to the FJ, but Donald says it works flawlessly. Fuel is provided via a 15-gallon aluminum fuel cell mounted below the tub floor. |
Building an extreme 4x4 that's ready for any challenge can prove to be a difficult proposition. It often entails a good bit of steps backward for every step forward and can take its toll on those eager to hit the trail in their new ride. Donald impressed upon us some of the factors that helped him keep his cool during the buildup. First off, know what you want before you start. Be realistic about cost and time, realize that modifications beget further modifications, and most importantly, have a lot of patience. With these guidelines in mind, maybe you'll find yourself in a ride like Donald's, crawling obstacles and cruising the highway.
A '98 5.7L Vortec V-8 is situated between the fenders and presented the biggest issues in the buildup of the rig. The mighty mill finally passed the stringent California smog laws after months of tweaking and testing by Jason Bunch of Tri County Gear. The engine is equipped with a K&N air filter and York engine-driven compressor.
SPECIFICATIONS
Year/make/model:
'80 Toyota FJ-40 Land Cruiser
Owner/hometown:
Donald Cassel/Venice, California
Engine:
'98 Chevy 5.7L Vortec V-8
Induction:
EFI
Transmission:
700R4
Transfer case:
Atlas 4.3
Frontend:
Dana 60 with ARB Air Locker
Rearend:
Dana 60 with ARB Air Locker
Ring-and-pinion:
4.88
Suspension:
Warn Black Diamond coil kit, Fox shocks
Tires/wheels:
39.5x12.50R17 Interco Irok/17x9.5-inch Allied bead locks