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Unread 06-08-2008, 12:06 AM   #1
bulldog
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Default Kurtfab diff bracket

Installed a Kurtfab passenger side front diff bracket. It was pretty quick and painless. The new bracket looks nicely beefed up and I doubt it will experience any failures down the line.

See this thread for more detail on the modded bracket
http://www.toyota120.com/forum/showthread.php?t=3102

To install this bracket will probably take 30mins at the most if your tools are already out. The hardest part is to remove the skid plate to get to it.

You will need the following tools:
19mm socket
22mm socket
Socket wrench
Breaker bar (might be needed if wrench doesn't have long handle)
TQ wrench
19mm wrench
Floor jack or bottle jack that can reach to the diff.

1: Remove the factory skid

2: Support the diff with the floorjack so it doesn't hang on just one side. No need to try to raise the diff, just gentle position the jack to hold it at current height.

I supported the diff under the pumpkin to allow for more workspace.



3: Next first just loosen the 3 bolts that hold the bracket in place. The larger bolts that holds it to the frame (marked in red) is 22mm, the other 2 bolts (marked in green) are 19mm.



4: Remove the rear most bolt that holds the bracket to the diff. Next remove the bolt that holds it to the frame, this bolt actually has a nut on top of the frame, which is 19mm (marked in green in the pic below). I held the nut with the 19mm wrench while removing the 22mm bolt below. Lastly remove the center bolt carefully to avoid the bracket from falling on you.

Make sure to note the top and bottom orientation of the bracket. The new bracket will look a bit different, so you need to double check everything. Also check the big fitment washers on the top and bottom of the bracket.



5: Put the old bracket next to the new one and make sure you have the right side to the top. Also double check to make sure you fit the large washers on it correctly. The washers might stick to the bracket so make sure you have one on the top and one on the bottom.

Old and new bracket



6: Install the new bracket. Use the center bolt to hold it first and then fit the front and back bolts. First just fit all 3 bolts and then lightly tighten all 3 bolts.

Finally TQ the bolts. The 2 diff bolts (marked green above) are 118 lb-ft and the frame bolts (marked in red) is 101 lb-ft (remember to hold the top nut when tightening the frame bolt).

New bracket in place



7: Remove support jack and reinstall skidplate. And feel comfy that you most likely will not break the bracket, which will take out your CV and sump at the same time.

Happy wheeling
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Unread 06-08-2008, 10:06 AM   #2
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what a great mod! I think this is a 'must do' for anyone. The potential failure is quite serious and this fix is so simple!
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Unread 06-08-2008, 10:28 AM   #3
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Originally Posted by Cruiserhead View Post
what a great mod! I think this is a 'must do' for anyone. The potential failure is quite serious and this fix is so simple!
Agreed and it should be pretty cost effective to get it from "Kurtfab". This is probably the best mod I have done to date from an "insurance" point of view, the magnitude of the potential failure vs the time and cost of the mod is very impressive.


I just hope it doesn't break anything else
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Unread 06-08-2008, 10:38 AM   #4
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well, let's see what damage we can do at BB!
Kurt, nice work- this is something anyone that goes offroad should get. Even stock, this is solid insurance. I would put this mod as a "must have"
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Unread 06-08-2008, 04:28 PM   #5
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Those new diff brackets look beefy, I'm sure those could take a beating !
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Unread 06-09-2008, 09:19 AM   #6
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Thanks for the write up and pics. If anyone is interested in getting a plated passenger side diff bracket then please shoot me a PM.
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Unread 06-10-2008, 06:10 PM   #7
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Nice write-up.
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Unread 06-24-2008, 05:11 PM   #8
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I built a few over the weekend and I have one left. If anyone is interested please shoot me a PM. It will probably be a couple weeks until the next batch.
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Unread 06-24-2008, 08:57 PM   #9
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Quote:
Originally Posted by 97kurt View Post
I built a few over the weekend and I have one left. If anyone is interested please shoot me a PM. It will probably be a couple weeks until the next batch.


If you want, send it to me, and I'll send you mine, and any others that we get extra.
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Unread 06-30-2008, 01:45 PM   #10
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nice writeup, pics and product.

Last edited by T?@\7; 06-30-2008 at 01:52 PM. Reason: needed to read Kurts thread
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Unread 07-22-2008, 10:39 PM   #11
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I finally installed the Kurtfab bracket.
Andries' instructions made it easy.
Thanks to Robert for help getting the "raw" bracket from Findlay.
And ofcourse thanks to Kurt for the Mod.

Bracket Mounted - Before & After.jpg
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Unread 07-23-2008, 10:32 AM   #12
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Quote:
Originally Posted by Chuck View Post
I finally installed the Kurtfab bracket.
Andries' instructions made it easy.
Thanks to Robert for help getting the "raw" bracket from Findlay.
And ofcourse thanks to Kurt for the Mod.

Attachment 824
Nice work! How much was the bracket from Findlay and what did Kurt charge for the fab work?

TIA
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Last edited by MAC4Runner; 07-23-2008 at 11:11 AM.
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Unread 07-23-2008, 01:39 PM   #13
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Quote:
Originally Posted by MAC4Runner View Post
Nice work! How much was the bracket from Findlay and what did Kurt charge for the fab work?
Got a nice discount from Findlay. PM Robert (my034runner) and he will set you up.
PM Kurt (97kurt) for the fab charge.
(Note: You don't have to buy a new bracket.)
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Unread 09-27-2008, 08:37 PM   #14
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Finally got around to putting mine on. Thanks, Kurt!

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Unread 09-28-2008, 08:04 PM   #15
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Put mine in this afternoon. Looks great. No pictures as it looks just like Mike's in the photo above.

Thanks again Kurt.
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Unread 09-29-2008, 12:50 PM   #16
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I put mine on the other day. Kurt shipped, charged and communicated perfectly throughout the transaction. I hate to sound like an Ebay review but for some it's scary to send money off into the 'wild blue yonder' and for Kurt he could develop a nice little cash-on-the-side gig. I feel like part of a group here, a group of decent people who share a passion for T120's. That comment probably wasn't necessary but I am sure someone has reservations and I'd like to see Kurt profit from his good work.

The bracket itself looks good with good welds and enough beef to prevent failure. It's actually more of a pain to do the skidplate R&R than it is to change the bracket. That's how easy the job is...

Overall I think it's a great mod and money well spent.
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Unread 09-29-2008, 01:58 PM   #17
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Is there a high risk of this failing if it is left with the stock bracket? Never even heard of this until now.
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Unread 09-29-2008, 02:13 PM   #18
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Quote:
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Is there a high risk of this failing if it is left with the stock bracket? Never even heard of this until now.
Not a high risk. I think there have been 3-4 failures on 4R's and FJ's, but the failure can cause LOTS of other problems- smashed oil pan, broken CV, etc. For me it was cheap insurance, even though I don't wheel as hard as many here.
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Unread 09-29-2008, 02:15 PM   #19
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Originally Posted by jbs11 View Post
Not a high risk. I think there have been 3-4 failures on 4R's and FJ's, but the failure can cause LOTS of other problems- smashed oil pan, broken CV, etc. For me it was cheap insurance, even though I don't wheel as hard as many here.
How much did it end up costing you?
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Unread 09-29-2008, 02:46 PM   #20
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Quote:
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Is there a high risk of this failing if it is left with the stock bracket? Never even heard of this until now.
Define "high-risk". This is the only failure of any kind I have seen evidence of in multiple vehicles. Some people break some things individually, but this is the only one I've seen numerous times on several vehicles. So far I would say it is the only item of "high risk" on the 120 platform, relatively speaking.
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