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1981 Toyota 4x4 Pickup - The Phoenix Project



The Deaver front leaf pack at the top is made of progressively spaced thin leaves. At bottom is an aftermarket leaf pack from another reputable supplier. Although they're both good, the design of the Deaver pack is better able to absorb both small and large bumps because of its multileaf, progressive design.
The Deaver front leaf pack at the top is made of progressively spaced thin leaves. At bottom is an aftermarket leaf pack from another reputable supplier. Although they're both good, the design of the Deaver pack is better able to absorb both small and large bumps because of its multileaf, progressive design.		I modified a pair of jackstands for extra height and stability. With the front end safely supported, the front axle was yanked free.
I modified a pair of jackstands for extra height and stability. With the front end safely supported, the front axle was yanked free.		The next step was to strip down the axle to a bare housing. It's a messy job because of the grease inside the steering knuckles but not an overly complicated operation.
The next step was to strip down the axle to a bare housing. It's a messy job because of the grease inside the steering knuckles but not an overly complicated operation.
The torque rod interferes with both the All-Pro tie rod and the All-Pro axle gusset, so it's gotta go. I used a cut-off wheel to delete it, but a Sawzall or a plasma cutter could have been used instead.
The torque rod interferes with both the All-Pro tie rod and the All-Pro axle gusset, so it's gotta go. I used a cut-off wheel to delete it, but a Sawzall or a plasma cutter could have been used instead.		A flap-disc wheel was used to clean off paint until only bare, clean metal was on the surface.
A flap-disc wheel was used to clean off paint until only bare, clean metal was on the surface.		All-Pro's gusset fits the top of the axle between the pumpkin and the driver-side spring perch. Some custom-contouring will be needed for a perfect fit. Since I'm using the TIG process to join the components, ideal fit-up was that much more critical. I decided to run a plate behind the holes in the gusset to keep water and debris out.
All-Pro's gusset fits the top of the axle between the pumpkin and the driver-side spring perch. Some custom-contouring will be needed for a perfect fit. Since I'm using the TIG process to join the components, ideal fit-up was that much more critical. I decided to run a plate behind the holes in the gusset to keep water and debris out.
Checking the fit often, I contoured the gusset with a grinder until the fit was dead-on. I tacked the gusset in place with multiple tack welds and then began to fuse the gusset to the housing with 1- to 2-inch stitches. Welding only a little at a time and allowing generous cool-off time between the welds minimizes warpage
Checking the fit often, I contoured the gusset with a grinder until the fit was dead-on. I tacked the gusset in place with multiple tack welds and then began to fuse the gusset to the housing with 1- to 2-inch stitches. Welding only a little at a time and allowing generous cool-off time between the welds minimizes warpage		Done.
Done.		All-Pro's differential armor is thick and does a superb job of protecting the ring gear from rock abuse. It welds on. I placed a weight on top to hold the armor in place and contoured a couple of edges for an ideal fit.
All-Pro's differential armor is thick and does a superb job of protecting the ring gear from rock abuse. It welds on. I placed a weight on top to hold the armor in place and contoured a couple of edges for an ideal fit.
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