Outer Limits 4x4 Board

This is for the LJ78 Import Prado
Its not as simple as it seems the bearing hubs are different and the stub and swivel housings are different.
To start you will need
-free wheeling hubs from Hilux leaf spring front end or Landcruiser 1982 to 1988 HJ or FJ60, 75, 61 or 62
-stub axles off same models as above
-bearing hubs from Leaf spring hilux with vented discs or Landcruiser HJ or FJ60, 75, 61 or 62
-cone washers, split washers and nuts
-swivel housings from one of the same models above, not enteirly nessisary
-axle seal kit
-wheel bearings, recomended but may not be nessisary
-new hub nut sets x 2

First step
Remove electric locking hub
a star torque bit set is needed available from most tool stores
loosen the 4 bolts to remove the outer cap

this will expose the lock nut

note the small torques star screws,

these are very small and can be tight I used tools purchased from J car electronics but be warned the screws can be so tight they can twist the end off the tool.
If this happens and you can not remove the locking screws you will have to try and knock off the locking tab on the lock nut with a coal chisel then use the coal chisel to knock the nuts around untill it falls off, it is a long process but it can be done!

once the lock nut is removed the hub nut can be undone with a hub nut tool, available from good 4wd specialists (Me!)

clamp main brake hose from chassis to diff, located on the drivers side, (I used vice grips but ther is special brake hose clamps for the job)
disconnect the pipe from the back of the brake caliper and remove brake caliper, then you can remove the disc and hub assembly.

then take off the circlip that holds the brake pipe

this will allow the backing plate to come over the end of the CV,

undo the 14mm bolts around the stub.

Very nice write up so far, keep it up!

Move the backing plate out of the way then knok off the stub

note the wire going into the top of the swivel housing

the wire is attached to the back of the stub

note the recess in the swivel housing, there is 2 ways of going about this
1. change the whole swivel housing with a standard Hilux or Landcruiser one
2. clean the hole where the wire was and fill the hole with sikkaflex - (do this before reassembly) I had to take it apprt again!

Reassembly
grease the brass bush and the gasket surface,( helps hold the gasket in place).
slide it on the CV
line up the bolt holes push it home, it should stay in place
run some grease around the outside for the next gasket to hold it in position

Re fit the backing plate and put the bolts back in and tighten them.
fit wheel bearings to hubs if needed and pack well with grease

the discs are the same as normal Landcruiser HJ75 etc as stated in the first instalment.

the ones I removed were rubbish so I used some near new ones that were still on the hubs that I needed.

Place the disc on the stub and push it home
it may need a little gentle persuasion especially if you have replaced the dust seal and hub seal.

place on the large washer then one of the hub nuts - tighten with hub nut tool by hand, the disc should be easy to turn with slight resistance.
put star shape locking tab washer on and finally the second nut and tighten, when tight use a screwdriver to bend up one or two of the edges of the lock washer and knock it flatagainst the edge of the nut.

pack a bit more grease into the hub and fit the gasket for the free wheeling hub.
re-fit the caliper and the brake pipes
Take off the clamp on the brake line and bleed the brakes

fit the wheels and
JOB DONE!

Nice work ,
Anymore pics of the rig
There is a guy in NZ that sell modded manual hubs to suit/replace elec hubs

no pics of the car it's a freinds car he got stuck on Moreton island, 4wd was'nt working so he asked if I could change it to manual hubs. At first I thought too easy! just unbolt the electric ones and bolt on manual ones, but as it turns out there was a whole lot of differences.