Simple LJ80 : Twin-stick mod with just one stick (how should i call it?)

Mono-Stick L2 Mod?

It is basically twin stick mod, but as lj80 has very limited space for the two stick (and they need to be bent which create problem for the pivoting mechanism), then i went back to drawing board and come with this Mono-Stick L2 Mod.

I need this mode as i have auto locker in the front diff. Having L2 switcable next to L4 makes easier to steer on tight spot, as well maybe i may use L2 more than L4 (maybe, why not?)

The recipe is to add new path from H-N-L control rod to jump back to 2wd-4wd control rod. And from there it is just a matter of pushing the lever upfront for 2L. Quite simple mod.

Time to test the mod. With one stick only, no modification needed on the cabin floor as well as it keep the old look the same. Mono-Stick L2 Mod !

Simple lj80 : attempt for twin stik

It was working when not inside car :) 

When transfer case installed back to car, the space was so limited that i need to bend the actuator plates, weld two short stiks to it for the handle. And when i push/pull the handle,it (instead selecting the gear) twist the plate around.

The actuator plate is just 5mm thick, soft steel, and smaller on the pivot area, that area can't hold force from side. 

Will try another mechanism later..

Simple LJ80: Speedometer sensor?

Dimension as pictured, shaft is 10mm. Sj410 use 8mm so it is not interchangeable. But the sj410 seal (8x16x5) still can be use (very tight)

Simple LJ80 : improving articulation

Mine was still with the stock shock absorber. Max travel was around 40cm.

Wondering if that can be improved, I tested my car into max articulation as possible by wheeling one front wheel into rock while the other front wheel into sewer/hole.  Then i removed the screws holding the shock absorber for the lower front wheel and the wheel dropped lower than before. It is maxed at 50cm. At the same time i measure the minimum travel on the upper wheel(on the other side) and i got 30cm. 

The old shock had 25cm to 40cm. While the new measurement is 30cm to 50cm. Calling my nearest spare part store i got one for toyota innova rear shock absorber which fit the new setting for front LJ80.

For the rear, I noticed the wheels doesn't articulate as much as front wheels. As I removed one link of swaybar/stabilizer it added some travel to the rear wheels. Negative effect is the body tilted more at the same setup. This may affecting the feel when offroading, and as well stability when cornering.

Simple lj80 : winch wheel fail

Vespa 12inch rim, welded to jimny disk-brake, mounted on the wheel with help of screws, spacer and modified wheel nuts.

Put the car on the ditch , 2wd-Lo (unlock the front hub), attach the winch to the wheel and tree in front. Result = failed.

Why, it is because the open rear diff. All power went to the left rear wheel as the right rear had more load due to wheel winch. 

Solution :

- need one more wheel winch to balance load

- or, use diff locker on rear

As there are no mechanism to hold the tension on the winch, i assume it shouldn't be use to pull vehicle uphill.

Simple Lj80 : Goodyear Extragrip 7.00 r15

It does provide extra grip, it is slim enough, yet tall enough, and somehow doesn't give that modern look like mud tires. 

I triend 7.50 r15 but it is too big that reduce articulation (hit the upper wall on slight flex. 7.00 is just enough 

Simple LJ80 : Differential locker !

What locker can be fitted to LJ80?

1. Spool, minispool or welded diff, cheap, reliable (if done properly), but may put much stress on the axles.

2. Auto-locker. I got 1520lr powertrax which can be fitted on front or rear "closed" stock diff. It use stock side gears and as it is autolocker, basically it will lock under gas/throttle and will release if coasting.

3. Selectable locker. 

I have been digging this option since there is cheaper Chinese air locker (Hflocker?) which is copy of arb and found that rd207 (for small diff front lj80 or sj410 early generation) is using 22spline shaft and 8bolts ring gear. Stock diff of lj80 is small "closed" diff, but 10bolt ring gear. There is sj410 diff (normally 8:41 or 8:43) which is small type (early generation) and as well "open"type diff. The open type diff has 8pinion bolts !! Some friend confirm that this work but you need to pay the cost of the locker, the new diff (front and rear) and as well the modification. And it work only for front 22spline axle shaft!

Based on that, i choose 1520lr in front diff. Why? it is cheap, it allows me wheel normal in 2WD event with front hub locked (slight ratcheting on turning, that's all). And still get traction on 4WD.

It get slightly difficult to turn, but the same i get when i use rear locker.

Why not autolocker in the rear diff?

Because it affect my 2WD quality as it lock the rear everytime i give throttle. Turning while throttling on slippery road may drift the rear wheels.

Front locker is pulling and better at riding/crawling obstacles. Rear locker will only push you forward bumping the obstacle.

A little note about closed/open type diff. - The closed diff mean the worm gear is inside closed diff housing. You can't see the worm gear/side gear without opening the side diff plate. It has 1 long pin and 2 short pin for the 4 worm gears.

1520lr locker works for this 3pins closed diff. 9:41 stock, 8:43, 11:51 diff mostly found as closed diff.

- The open diff mean you can see worm gears and side gear directly. It has 2worm gears and 1pin and i belive bigger side wheel. It is normally found in 8:41 and some rare 8:43 diff.

Having a diff locker, the power delivered under control, no wheel spinning (other than when needed), no trail damage, less shock on axles (it is not brute force !).

And my 2WD is not affected at all. Auto-locker in front is perfect for daily driver !