BJ40 Buggy Project

We are doing a total rebuilding of a Toyota BJ40 Buggy which is near completion, details photos and updates of the whole process can be found at TBK Offroad Performance Page.  Here is the summarized list of what we did.

Rear 4 link suspension by TBK Offroad Performance

Toyota BJ40 Buggy Upgrades Parts
- Toyota 15B turbo diesel engine
- Front & rear FJ80 axle housing swap
- Chromoly axle anners
- ARB air lockers
- 5.29 Ring & Pinions
- Front & Rear 4 link suspension , with chromoly rod ends, aluminium alloy links
- Trail Gear assorted link brackets
- Fox 3.0" remote reservoir coil over shocks and 2.0" bumps
- Maxxis 40" Trepador with internal beadlocks
- TBK Offroad Performance customized cage
- Modified H55F transfer case for Dual PTO winch
- Trail Gear's full hydraulic steering Kit
- Trail Gear long travel drive shaft extension


 

Like our previous LC40 project the decentralized axle differential complicates the rear 4 link suspension, with previous experience and due to fact that this is a buggy , we get less restriction from blocking fuel tank and body parts. The transfer case are raised and wheel base extended to accommodate a longer drive shaft and larger travel.  

A triangulated or double triangulated arrangement of the suspension remove the requirement of the panhard rod and increase articulation. With coil-over shocks and hydraulic steering leaves the axle less "congested" ,  it looks cleaner and have more space for access. 

2" aluminium alloy links are use on all 4 links at the front. On the rear the upper links are 2" while the lower link 3" . The 3.0 heavy duty Fox coil-over shocks are mounted on the lower links with a fabricated OD clamp.    

The Modified H55F transfer case had two outputs for PTO winch. A Prado 90 clam-shell differential with stock 4.56 ratio is used to drive the winch drum. Due to the lower ratio , these winch are typically very much faster than the standard PTO. These setup are also much durable and often known as Fast PTO. 

We are left with wiring of the engine,mounting of the PTO and some other minor aesthetic touch up. Completion will due August and will make it for an October 4x4 event in China, co-organised by the Malaysian Rainforest Challenge Committee.

Courtesy of our endorsed and trusted workshop. 

TBK Offroad Performance 
No.19 , Jalan Bakawali 35
Taman Johor Jaya, JB, Malaysia 
Contact: Mr Tay Beng Khiat  (+6010-6666839)

BJ40 Buggy Videos