4Crawler Offroad Products - Driveshaft Spacers for Toyota, Ford, Dodge & Chevy Vehicles

Drive Shaft Spacers for Toyota, Ford, Dodge & Chevy Vehicles

4Crawler Offroad Products

Fits many Pickup, 4Runner, Tacoma, Tundra, Landcruiser models

also may fit Mitsubishi Montero, Pajero, MityMax and Dodge D50 pickups.

And now available for the Ford 8.8/9/9.75/ (9") and other flanges and the Dodge/Chevy flanges

A product of Visual Diagnostics LLC

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Contents:

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Introduction:

On the Toyota 4WD Pickup, 4Runner and Land Cruiser model, the front and rear drive shaft bolt to "companion" flanges on the transfer case with a mating flange on the drive shaft (Propeller Shaft in "Toyota-speak"). On the 2WD pickups, the drive shaft typically slides into a slip yoke output on the transmission and bolts to the rear differential with a flange. Up until now, the only way to make a drive shaft longer was to remove it and have a drive line shop cut the existing tubing off the drive shaft and weld on a new length of tubing. If you needed a significant change in length, this was not so bad to do. But often, you only needed to lengthen the shaft a small amount, from 3/4" to 1-1/2" for example. Since you had pay for a whole new length of drive shaft tubing (plus the labor to install it) and not just the additional inch or so of additional tubing, it could cost hundreds of dollars to have a shaft lengthened, even a short amount. On the other hand, shortening a shaft is typically less expensive, since you can simply separate one end from the shaft tubing, cut the remaining shaft down and re-weld the end back on.

What are some indications that your drive shaft is too short?

Ideally, you only want just a little more slip yoke compression travel than needed by the change in drive shaft length as the suspension fully compresses. How much is that? It is hard to give an exact answer, as every vehicle is different. Generally a rear drive shaft needs less slip yoke travel than a front drive shaft. A longer drive shaft generally needs less slip yoke travel than a shorter one. A drive shaft that is at a flatter angle will generally need less travel than one at a steeper angle.

How much spacer do I need?

So how do you determine how much slip yoke travel you need on your vehicle?

Generally having too much slip yoke compression travel is better than not enough. Whatever you do, you do not want the drive shaft to "bottom out", as that can cause severe damage to the transfer case, as it will take the brunt of the impact should the slip yoke compress fully. But if you have so much slip yoke pull apart that it separates or vibrates is no good either.

There is one situation where a drive shaft spacer may not be an option and that is where a short drive shaft is already running at an extreme angle and/or the joints are near their maximum operating angle. Since installing a spacer effectively shortens the distance between the ends of the shaft (that is how the spacer makes a too short shaft fit), it also will make the angles increase. Normally this is not a big issue on a longer shaft, but on a short shaft where you are already running at the maximum joint angles, the angle change of the spacer may be too much to accommodate. In this case physically lengthening the shaft is the better, albeit more expensive, option.

Until now there has only been one solution, that is to have the shaft physically lengthened at considerable expense. But now available for the Toyota 2WD and 4WD pickup, 4Runner, Tacoma and FJ-series Landcruiser models are some simple bolt-on spacers that fit many of the common drive shaft bolt patterns and typical applications listed below. The bolt pattern dimensions are illustrated in this sketch. The three dimensions you'll need to determine the bolt pattern are labeled "X", "Y", and "Z". X and Y represent the center-center spacing of the pattern on each side while Z is the size of the bolt that goes through the flange, typically 8mm, 10mm or 11mm. Note that the actual holes in the flange are typically slightly oversized, so if you measure 10.2mm hole diameter, that implies a 10mm bolt.

Drive Shaft Flange Dimensions:

Drive shaft flange sketch

The pilot dimension is that of the ring in the middle of the flange that keeps the drive shaft properly centered.

Toyota Companion Flange Dimensions:

All have a 46mm diameter pilot ring. See note below if your driveshaft flange uses studs instead of through bolts...

Bolt Pattern/Metric Bolt Size Bolt Pattern/SAE
(approx.)
Typical Application
60mm x 60mm 8mm 2-23/64" x 2-23/64 1979-1983 U-Joint*
56mm x 64mm 8mm 2-13/64" x 2-33/64" 1979 - 1983 U-Joint**
56mm x 64mm 10mm 2-13/64" x 2-33/64" NEW: FJ-40 Landcruiser****
60mm x 60mm 10mm 2-23/64" x 2-23/64" 1984-1995 U-Joint
also FJ-80/LX-450 front
60mm x 68.5mm 10mm 2-23/64" x 2-23/64" 1984-1995 CV Joint/4cyl
61.5mm x 70mm 10mm 2-27/64" x 2-45/64" 1988-1995 CV Joint/V6
also: FJ-60
65mm x 65mm 10mm 2-9/16" x 2-9/16" 1995.5-200x Tacoma CV
1996-200x 4Runner CV
2005+ Tacoma 2WD pinion flange
Tundra 2WD pinion flange***
66mm x 66mm 11mm 2-19/32" x 2-19/32" FJ60 differential flange *****
Tacoma/Tundra
4th gen 4Runner/FJ Cruiser
77mm x 77mm 11mm 3-1/32" x 3-1/32" Tundra *****
88mm x 88mm 11-12mm 3-15/32" x 3-15/32" Tundra *****

Ford Pinion Flange Dimensions:

Bolt Pattern Bolt Dia. Pilot Dia. Typical Application
2.5" x 2.5"
~3.5" BCD
12mm 2.0" Passenger Cars
3.0" x 3.0"
~4.25" BCD
12mm 2.0" F-150 and up pickups
Explorer
Mustang
3.375" x 3.375
4.75" BCD"
12mm > 2.0" F-350/1 ton
pickups

Dodge/Chevy Flange Dimensions:

Bolt Pattern Bolt Dia. Pilot Dia. Typical Application
3.0" x 3.0"
~4.25" BCD
7/16" ~3.1" Dodge Ram pickup, etc.
3.0" x 3.0"
~4.25" BCD
7/16" ~3.1" Chevy pickup, SUV, etc.
3.0" x 3.0"
~4.25" BCD
7/16" ~2.18" Dodge 2WD pickup, etc.

The spacers are machined from billet T-6061 aluminum and are 107mm or 127mm in diameter (does not need to match the outer diameter of the transfer case or pinion flange exactly) and include 4 - 8mm, 10 mm, 11mm or 12mm metric grade 12.9 mounting bolts and class 10 lock nuts (where needed) to replace the stock mounting bolts. These spacers feature a male locating ring on one side (~3mm high) and a corresponding female recess (4.5mm deep) on the back side to fit the corresponding ring and recess on the stock drive shaft and companion flanges. To check what drive shaft flange bolt hole spacing will work on your truck, measure the center-center bolt hole spacing and compare to the above dimensions and see if you match up with one of the above bolt hole patterns,

When measuring the bolt hole patterns, it might help to imagine a square (or rectangle) formed by the 4 bolt holes in the flange. The corners of the square (or rectangle) will fall upon the center of the bolt holes and it is the width (and length) of that square (or rectangle) that define the bolt hole pattern. For example, if you drew a 60mm x 60mm square then drilled a hole at each corner of that square, you would end up with a 60mm x 60mm bolt hole pattern. This is contrasted to a Bolt Circle Diameter (BCD) measurement which is commonly used on measuring wheel stud locations. For example, a Toyota 6-lug wheel BCD is 6 on 5.5", meaning 6 holes equally spaced around a 5.5" diameter circle. The problem with BCD is that it assumes the bolt holes are equally spaced and while it would work with the square bolt patterns, it does not work for the rectangular patterns as you can't specify where the bolt holes are located along the bolt circle.

Notes:

What makes the 4Crawler Offroad spacers different?

So, what makes these spacers different? First off, our spacers are designed and manufactured 100% in the United States.

Well, we were one of the first companies offering a Toyota-specific drive shaft spacer and have now expanded into the Ford, Chevy and Dodge vehicles. In designing our spacers, we studied the market and picked the most popular set of drive shaft flange bolt patterns to support. As such, we offer the widest variety of patterns and spacer sizes available on the market. We also offer blank, un-drilled spacers for those cases where you may have a unique pattern or application. And over the years, we have increased our product offering by adding the newer 65mm x 65mm pattern as well as the older 56mm x 64mm pattern plus the new 11mm bolt patterns on the newer Toyota trucks.

Also, we only use metric bolts where applicable, unlike some of the other spacers out there, which use undersized SAE hardware. Also, we use grade 12.9 hardware, meeting or exceeding the specs. of the factory grade 11 hardware. And also, we list the exact bolt patterns of each of the spacers, so you can check which one meets your needs before you order. Since there is such a wide range of bolt patterns that have been used over the years on a wide variety of vehicles, it is hard to list a spacer that fits any given year/model vehicle. Also, with the popularity and ease of swapping parts from one vehicle to another, you may have a 'XX 4Runner with a transfer case from a 'YY pickup and a drive shaft from a 'ZZ Tacoma, and deciding what "year" your vehicle is for purposes of selecting a spacer for is pointless.

Note on hole vs. bolt size:

Drive shaft flanges are held together with 4 bolts typically that fit through the holes in the two flanges, and the spacer, if present. This bolted joint transfers the torque through the mechanism of clamping friction. That is, it's the normal force supplied by the clamping bolts, that are under tension, coupled with the coefficient of friction of the flanges and spacer that allow torque to be transferred across the bolted connection. Contrary to popular belief, torque is not transferred via the flanges loading the bolts in shear. The only way this can happen is if the bolts are too loose and allow the flanges to rotate against each other until it's only the bolt shanks that are under load. If the flanges were meant to be loaded it in this fashion, the bolts would need to be pressed into interference fit holes to ensure all 4 bolts were equally loaded in shear. But, you'll observe that the factory bolt holes are drilled out somewhat larger than the bolts to allow for easy assembly. Here's a good discussion of this topic on the Eng-Tips forum. So this is the reason the holes in the spacers are drilled somewhat oversize, both to allow for easier installation and to allow for varying bolt patterns and bolt diameters to be used.

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On-Line Ordering:

Order a drive shaft spacer below:

Shipping cost/time via USPS Priority small or medium flat rate box

Our default shipping method is USPS mail and default payment option is Paypal. If you wish to use a different shipping or payment method, please contact us prior to ordering. Let us know the item(s) you want, where and how you'll want them shipped to and we'll get back to you with a shipping quote and purchase information:

4Crawler Offroad contact link MissingLinkZ contact link

UK NOTE: Beginning 01.Jan.2021, we'll no longer be able to accept orders shipping to the UK via our on-line order system due to the VAT requirements. Click here for alternate ordering options.

You can check the USPS shipping suspension page for world-wide shipping status.

Returns and exchanges
Cancellation Policy

Want the spacers shipped faster?

Use the order buttons below to upgrade the normal Priority Mail postage to Express Mail. For Australia orders, this is required as Priority Mail is currently not being accepted until furhter notice. If you would like to use UPS or FedEx shipping, contact 4Crawler Offroad for details before placing and order.

Quantity:

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Express Delivery upgrade; US$18.50 for US shipments Express Delivery upgrade; US$32.00 for Int'l shipments

8mm hardware options:

For customers needing 8mm hardware, the first option is we can supply 8mm hardware along with the default 10mm hardware. This gives you the choice of running 8mm hardware w/o re-drilling your flanges and then later you could drill the flanges and have the larger 10mm hardware on-hand. The second option is we can supply 8mm hardware instead of 10mm hardware, just let us know at the time of ordering..

Quantity:

Add 8mm nuts/bolts to spacer order

Hardware-only options:

NOTE: Our spacers come with 4 longer than stock bolts. However, we do have the spacer hardware available separately in case you need different size hardware, you lost the hardware, or are installing a spacer on a different vehicle or maybe you received a spacer from someplace else and need hardware for it. A kit of 4 bolts (washers, nuts) as applicable is US$25.00 plus postage:

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Add spare h/w to spacer order Order replacement h/w - US shipping Order replacement h/w - Canada shipping Order replacement h/w - Int'l shipping

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5X-drilled spacers:

Our new 5X -drilled spacers provide 5 popular flange bolt hole patterns in a single spacer. This is an advantage in that many vehicles that use any of thesebolt hole patterns often use one or more of the other patterns as well. Normally with 5 sets of 4 holes, there would be a total of 20 holes in the spacer. However, by re-using some holes for multiple patterns, we're able to fit 5 (or 6) patterns into the same 12 holes as our original triple-drilled spacer had. This has allowed us to make a "one size fits all" spacer for the 10mm hardware.

We have had customers who intended to install a spacer on one drive shaft flange but for one reason or another, had to move the spacer to another flange with a different pattern. By having multiple patterns in one spacer, you can usually make that swap without having to exchange one pattern spacer for another. And to be clear, this spacer will fit any one of the 5 patterns listed below with 8mm or 10mm bolts. The 10mm bolts are socket head (needs 8mm allen key) to ensure a smaller head size to fit the cramped u-joint and cv-joint flanges:

  • 60mm x 60mm
  • 60mm x 68.5mm
  • 61mm x 70.5mm
  • 56mm x 64mm
  • 65mm x 65mm
  • They will also fit the 66mm x 66mm bolt hole pattern using 10mm bolts, perfect if you have a smaller diameter flange.
    • Spacers are 4-1/4" (105mm) diameter, a close match to the 4-3/8" flange
    • There's overlap in the ~11.5mm holes in the flanges and the ~10.5mm holes in the spacer. The 10mm bolt may fit as-is or the holes might need a little work with a round file or drill bit to clean them out to fit the bolts in.

Inventory:

Size--------Part Number-----Cost(US$)---Status 
0.50"/13mm - DSpcr5X_0.50 - $65.00 - In-stock 
0.75"/19mm - DSpcr5X_0.75 - $68.00 - In-stock 
1.00"/25mm - DSpcr5X_1.00 - $71.00 - In-stock 
1.25"/32mm - DSpcr5X_1.25 - $74.00 - In-stock 
1.50"/38mm - DSpcr5X_1.50 - $77.00 - In-stock 
1.75"/44mm - DSpcr5X_1.75 - $84.00 - In-stock 
2.00"/50mm - DSpcr5X_2.00 - $91.00 - Will include a 1.5" and 0.5" with longer bolts

Spacer includes grade 12.9 10mm bolts/washers/lock nuts

We HIGHLY recommend that you measure the bolt hole spacing on the flange you intend to install the spacer prior to ordering.

To order, select the desired spacer height and quantity, then click the Buy Now button to proceed.

10mm 5X Driveshaft Spacer 10mm 5X Driveshaft Spacer 10mm 5X Driveshaft Spacer
US Shipping Canada Shipping Int'l Shipping
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  • Shipping cost/time via USPS Priority small flat rate box
  • Please be sure to double check your shipping address, both that it is correct and that it is able to receive US Mail deliveries.

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11mm bolt - 66mm x 66mm and 77mm x 77mm spacers:

These spacers are larger in diameter (~5"/125mm) to fit the larger bolt patterns (i.e. 2 sets of holes 66mm x 66mm and 77mm x 77mm)and also have the larger 11mm holes and hardware. Note that you'll be using the bolt pattern that lines up to your flange and not using the other holes. If you have just the 66mm x 66mm flange and want a smaller diameter spacer, you can order this smaller diameter spacer and it should fit that bolt pattern using the 10mm bolts. With a 4-3/8" flange and a 5" dia. spacer, you'll have ~5/16" or 8mm of spacer sticking out past the flange.

This spacer is often used on the popular 4th gen. 4Runner modification of installing a transfer case out of an FJ Cruiser. For this swap, the rear drive shaft needs to be lengthened 1" - 1-1/2". So the 66mm x 66mm spacer in either of those heights is recommended.

We HIGHLY recommend that you measure the bolt shank diameter and hole spacing on the flange you intend to install the spacer prior to ordering.

11mm bolt spacer
11mm bolt spacer and hardware
Inventory:
Size-------Part Number---Cost(US$)--Status
0.50"/12mm - DSpcr-11_0.50 - $72.00 - In-stock
1.00"/25mm - DSpcr-11_1.00 - $78.00 - In-stock
1.50"/38mm - DSpcr-11_1.50 - $84.00 - Will include 1.0" and 0.5" spacers

  • Spacer includes grade 8 bolts/washers/lock nuts:
    • For the 1.50" spacers, the 4-bolt option includes 1 set of bolts sized for the stacked spacers
    • For the 1.50" spacers, the 8-bolt option includes 2 sets of bolts sized for the separate spacers
      • This allows for one spacer on each end of the drive shaft
  • They are approx. 5" or 125mm in diameter

    To order, select the desired spacer height and quantity, then click the Buy Now button to proceed.

    US Delivery Canada Delivery Int'l Delivery
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    11mm bolt - 66mm x 66mm, 77mm x 77mm and 88mm x 88mm spacers:

    For the larger 88mm x 88mm bolt pattern, this spacers uses partial holes around the circumference. The 11mm bolts will end up near the outer edge of the spacer in this configuration. The aluminum part of the spacer is ~5" or 125mm in diameter. The kit includes a trim ring made of tough ABS plastic that extends the spacer to ~6" or 150mm diameter. This ring covers the bolts around the outside, if desired. These spacers will also fit the 66mm x 66mm and 77mm x 77mm bolt patterns without the trim ring.

    We HIGHLY recommend that you measure the bolt hole spacing on the flange you intend to install the spacer prior to ordering. Some models may also use 12mm dia. bolts, this will also work with these spacers, although they will ship with 11mm bolts.

    Inventory:
    Size-------Part Number----Cost(US$)--Status
    0.50"/12mm - DSpcr-88_0.50 - $102.00 - In-stock
    1.00"/25mm - DSpcr-88_1.00 - $108.00 - In-stock
    1.50"/38mm - DSpcr-88_1.50 - $114.00 - Will include 1.0" and 0.5" spacers
    • Spacer includes grade 8 bolts/washers/lock nuts:
      • For the 1.50" spacers, the 4-bolt option includes 1 set of bolts sized for the stacked spacers
      • For the 1.50" spacers, the 8-bolt option includes 2 sets of bolts sized for the separate spacers
        • This allows for one spacer on each end of the drive shaft
    • They are approx. 5" or 125mm in diameter
    88mm x 88mm spacer
    US Delivery Canada Delivery Int'l Delivery
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    Notes:

    • Shipping cost/time via USPS Priority small flat rate box
    • Please be sure to double check your shipping address, both that it is correct and that it is able to receive US Mail deliveries.

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    Ford 8.8/9/9.75" Spacers:

    Now available for the Ford 8.8/9/9.75" and other pinion flanges with the 2" diameter pilot bore and the following bolt hole patterns:

    • 2.5" x 2.5" or ~3.5" BCD, ~4.25" dia.
    • 3.0" x 3.0" or ~4.25" BCD, ~5" dia.
    • To be clear, the spacers have BOTH bolt patterns or a total of 8 bolt holes. You simply use the 4 holes that match your flange and don't use the other 4 holes.

    Note that while the spacers may refer to Ford 8.8", as long as the flange you are attaching them to has one of the above bolt patterns and a 2" pilot ring diameter, the spacer will fit that flange. Makes no difference to the spacer if that flange is on an 8.8", or 9.75" differential.

    Some Ford flanges will be tapped for 7/16", either fine (NF or 20tpi) or coarse (NC or 14tpi) thread. If you need to use that size hardware, be sure to select that option in the order form instead of the default M12 option. We HIGHLY recommend that you measure the bolt hole spacing on the flange you intend to install the spacer prior to ordering.

    These spacers may also work with Atlas transfer case flanges that often have a 2" pilot ring and 3" x 3" bolt pattern. Those flanges often have 1/2" bolts, so be sure to select the no bolts option when ordering. The holes in the spacers will just fit a 1/2" bolt but you may need to slightly enlarge the holes if needed.

    For the larger 3.375" square bolt pattern, the flanges typically have a pilot bore diameter greater than 2" and these spacers will not fit. If you have the different bolt pattern and the 2" pilot bore, we can provide a modified spacer that will fit the larger bolt pattern. Contact 4Crawler Offroad for details.

    Ford 8.8 Spacer, Flange and u-joint yoke Ford 8,8 spacer installed
    Ford 8.8" Spacer, Flange and u-joint yoke Ford 8.8" spacer installed Ford U-joint flange example

    The spacer will fit in between the u-joint flange and pinion flange on vehicles equipped with a bolted flange. Some models don't have a bolted flange and rather have a u-joint yoke install on the pinion. If you wish to install a spacer on that type of setup, you'll need to change to a flange setup. On the lower end of the drive shaft, you'll install a u-joint flange, as shown in the above right image. Then on the pinion, remove the u-joint yoke and install a flange. You'll need to order the two flanges to match your u-joint and pinion, check out the ordering details on the Drive Train America web site. If doing this conversion, be sure to install the new flanges prior to measuring for the thickness of spacer you need. The flange setup will likely affect the shaft length and you'll want to account for that before selecting a spacer. Note that Drive Train America doesn't carry the spacers, they will supply the various flanges needed to convert your non-flange drive shaft to be able to use the 4Crawler Offroad spacers.

    Ford spacer questions.
    Size-------Part Number-----Cost(US$)--Status
    0.50"/13mm - DSpcr-F8.8_0.50 - $71.00 - In-stock
    0.75"/19mm - DSpcr-F8.8_0.75 - $76.00 - In-stock
    1.00"/25mm - DSpcr-F8.8_1.00 - $81.00 - In-stock
    1.25"/32mm - DSpcr-F8.8_1.25 - $86.00 - In-stock
    1.50"/38mm - DSpcr-F8.8_1.50 - $91.00 - In-stock
    1.75"/44mm - DSpcr-F8.8_1.75 - $101.00 - In-stock
    2.00"/50mm - DSpcr-F8.8_2.00 - $111.00 - In-stock

    Each spacer comes with 4 - M12x1.75 12-point flanged ARP or Darling (or 7/16") bolts long enough to accommodate the thickness of the spacer

    Ford 8.8 Spacer

    Order with US delivery below:

    0.50" Ford 8.8" Spacer 0.75" Ford 8.8" Spacer 1.00" Ford 8.8" Spacer 1.25" Ford 8.8" Spacer

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    1.50" Ford 8.8" Spacer 1.75" Ford 8.8" Spacer 2.00" Ford 8.8" Spacer .

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    Order with international delivery below:

    0.50" Ford 8.8" Spacer 0.75" Ford 8.8" Spacer 1.00" Ford 8.8" Spacer 1.25" Ford 8.8" Spacer

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    1.50" Ford 8.8" Spacer 1.75" Ford 8.8" Spacer 2.00" Ford 8.8" Spacer .

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    Notes:

    • Shipping cost/time via USPS Priority small flat rate box
    • Please be sure to double check your shipping address, both that it is correct and that it is able to receive US Mail deliveries.

    Here are 0.25" tall spacers that can be stacked on top of any of our Ford 8.8 spacers to achieve greater heights.

    We can also combine the billet aluminum spacers for taller heights as well. The billet aluminum spacers have the mating pilot ring/hole so will stack more precisely than the 0.25" spacers that only have a pilot hole. Another option for a 2.25" spacer would be 1.75" + 0.50" for example. This stack would include bolts sized for 1.75" as well as 2.25" at no extra charge.

    The combined spacer stack will come with 12mm 12-point bolts of the appropriate length for the combined spacer stack. Heights over 2.25" may require extra time as we don't stock the hardware in those sizes. Contact us for more information. Likewise, if you have a very tight installation area and need shorter bolts, let us know. By default, the spacers come with bolts that are ~35mm longer than the spacer height, e'g' 1"/60mm, 1.5"/70mm. We can supply bolts 10mm shorter than normal if you are tight on space.

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    Dodge/Chevy 9.25" (and other) Spacers:

    Now available for the Dodge/Chevy 9.25" and other pinion flanges with the ~3.1" diameter pilot ring with the bore about 3.125" and the following bolt hole pattern:

    • 3.0" x 3.0" or ~4.25" BCD, ~5" dia.
      • 3-1/8" pilot ring, or
      • 2-3/16" pilot ring

    We HIGHLY recommend that you measure the bolt hole spacing on the flange you intend to install the spacer prior to ordering, there are other bolt patterns and this spacer will not fit them. For example, the large 4-3/4" BCD (3-11/32" hole spacing) with a 3-3/4" pilot diameter is too large for this spacer.

    Dodge/Chevy Drive Shaft Spacer
    Dodge/Chevy 3" x 3" bolt pattern

    The spacer will fit in between the u-joint flange and pinion flange on vehicles equipped with a bolted flange. Some models don't have a bolted flange and rather have a u-joint yoke install on the pinion. If you wish to install a spacer on that type of setup, you'll need to change to a flange setup. On the lower end of the drive shaft, you'll install a u-joint flange, as shown in the above right image. Then on the pinion, remove the u-joint yoke and install a flange. You'll need to order the two flanges to match your u-joint and pinion, check out the ordering details on the Drive Train America web site. If doing this conversion, be sure to install the new flanges prior to measuring for the thickness of spacer you need. The flange setup will likely affect the shaft length and you'll want to account for that before selecting a spacer.

    There is a second variation of the Dodge/Chevy pinion flange. It uses the same outer diameter and bolt pattern, but it features a smaller pilot circle, that being approx. 2-3/16" We can make a spacer for this application by machining off the ~3" dia. pilot ring and then providing a 3D printed insert for the larger bore spacer. The insert only serves as a locator for centering the spacer on the pinion and drive shaft flanges and it serves no structural purpose. Order the "-S" version of the spacer to get the pre-machined spacer and adapter. If unsure which version flange you have and you don't want to check prior to ordering, you can order the -S version and let us know you don't want us to machine off the existing pilot ring. This way, if you find you have the larger bore flange, you can use the spacer as-is. If you find you have the smaller bore, then you can use the insert, but you'll need to machine, grind or file off the existing ring before the spacer will sit flush on the flange.

    Inventory:
    Size-------Part Number------Cost(US$)--Status
    1.00"/25mm - DSpcr-D9.25_1.00-L - $81.00 - In-stock
    1.00"/25mm - DSpcr-D9.25_1.00-S - $99.00 - In-stock

    Spacer includes grade 8 7/16"-NC bolts/lock washers. Spacer in 1.0" thickness at this time, made of billet T-6061 aluminum.

    With the small ring spacers, we can machine the raised pilot ring off or we can leave it in place.
    If you're unsure of the exact dimensions on your flange, leaving the ring intact lets you fit either sizer pilot with this spacer
    Also, if you're fitting a small ring drive shaft to a large ring pinion flange, you can do that with the pilot ring left in place

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    DSpcr-D9.25_1.00-L DSpcr-D9.25_1.00-S
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    Notes:

    • Ships via USPS Priority small flat rate box
    • Please be sure to double check your shipping address, both that it is correct and that it is able to receive USPS deliveries.

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    Returns/Exchanges Policy:

    • Exchanges:
      • If an exchange is desired, please include a note as to what exchange part you want and include return postage for that part to be sent back to you.
        • Return postage will be be as noted above, typically what the original item shipping was.
      • If you are in a rush to get the exchanged part, place an order for the new part and we'll ship that to you right away. Then return the old part, and upon receipt, we'll issue a refund against the new order.
    • Parts may be returned for a refund within 60 days of original purchase.
      • No need to obtain an RMA number or anything like that.
      • A 10% restocking fee will be deducted from original purchase price less outgoing shipping.
        • Parts must be in new and unused condition for the refund.
          • Used or blemished parts can yield partial refunds at the discretion of 4Crawler Offroad.
          • Parts that have been modified by the customer or that have been built to unique customer specifications are generally not refundable.
          • Returned items with missing components will have the refund adjusted for the cost of the missing items (e.g. missing nuts or bolts, etc.)
        • The customer is responsible for return shipping charges.
        • Returned parts must include a copy of the original invoice or packing slip for proper credit.
        • It is highly recommended that a package tracking number be obtained from the shipper and that that number be transmitted to 4Crawler Offroad so that we are aware that you have sent an item back and that we can track it, know when it arrives and can pick it up at our PO box.
          • If you use the USPS.COM on-line shipping label system, you can get the delivery/tracking number at no additional cost and you can simply enter our e-mail address (sales@4crawler.com) in the recipient field and we'll automatically be sent that information.
          • If you don't have a tracking number, at least send us an e-mail noting when and how you shipped the package so we can keep an eye out for it to arrive.
      • One exception to this policy is in the case that the parts do not fit properly, per the installation instructions.
        • The returned part(s) must be accompanied by photos or a detailed description of the fitment issue.
        • In such a case 4Crawler Offroad will refund the full purchase price less shipping. And as noted, please furnish a detailed description of the fitment issue reported, including dimensions, so that this fitment issue may be corrected for future orders.
      • Items returned 60 days or more past the purchase date will be refunded less any applicable transaction fees, typically 4% - 5%.
        • This time is from the date of purchase until we get our hands on the returned item(s) so we can inspect them for missing parts or damage, so be sure to allow enough time if planning to return an item for a refund.
      • Items that are custom built to fit customer specifications may only be returned for partial credit at the discretion of 4Crawler Offroad.
    • Return to:
      • 4Crawler Offroad Products
      • attn: Roger Brown
      • PO Box 61092
      • Sunnyvale, CA. 94088-1092
      • USA
    • Physical shipping address can be provided for UPS/Fedex return shipments if requested.
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    Installation Instructions:

    Installed spacer
    Installed spacer on transfer case
    output flange

    Allow approximately 30 minutes for the installation, assuming you don't run into any rusted or damaged fasteners. To install, you'll need:

    • Toyota 10mm: A pair of 9/16" or 14mm wrenches for the stock hardware and an 8mm long arm allen key and a 17mm wrench to install the new hardware
    • Toyota 11mm: A pair of 9/16" or 14mm wrenches for the stock hardware and a pair of 5/8" or 16mm wrenches to install the new hardware
    • Ford/Toyota 12mm: You'll need a 12-point socket or closed end wrench, typically 12mm or 14mm.
    • Dodge 7/16": A pair of 5/8" or 16mm wrenches to remove the old and install the new hardware

    While you should not have to separate the drive shaft to install the spacer, it is a good idea to put an alignment mark across both sides of the slip yoke. Some white paint works well and will help you re-align the slip yoke if you accidentally pull it apart.

    Typically, the stock Toyota drive shaft (a.k.a. propeller shaft) flange bolts use a 14mm head, so you'll need a pair of 14mm combination wrenches to remove those. For the rear drive shaft, block the vehicle's tires or place the rear axle on jack stands for easier removal. You can place the transmission in neutral and release the parking brake if needed.

    The spacers can be installed on either the upper or lower end of the drive shaft, depending on application and bolt hole patterns. On 4WD trucks, they are typically installed at the transfer case companion flange. 2WD trucks will only be able to install them at the pinion flange on the axle, but no reason 4WD trucks can't do the same. And it would not be out of the question to install two spacers on one drive shaft if you need to extend it more than 1.5", putting one spacer on each end of the shaft.

    Break the stock flange bolts loose at the transfer case and then remove them. Support the drive shaft before removing the last bolt to keep it from falling. Then compress the slip yoke enough to allow insertion of the spacer.

    Note:
    Some companion (transfer case or differential/pinion) flanges have pressed in studs instead of separate bolts. In this case, you'll need to hammer or press the studs out. You can spin a nut on the end of the stud before hammering it out to protect the threads. The supplied bolts will replace the studs.

    Then slip the spacer in between the transfer case output flange and the drive shaft flange and turn it to make sure you have the proper set of 4 bolt holes in alignment. Slip in one of the supplied metric socket head cab screws, a lock nut and washer (if needed). Repeat for the other 3 bolt holes, just to make sure all 4 bolts are installed before tightening them. If you find the bolts hard to install, use a small round file or drill bit to clean out the insides of the holes in the flanges to make installation easier.

    For the 5X drilled Toyota spacers, you'll note holes af varying sizes. Just find 4 that line up with your flange bolt pattern. The varying size holes are there to allow for re-use of holes for multiple bolt patterns. If we didn't do this, there would be 20 holes in each spacer, instead of the 12 that are there.

    There are varying thickness flanges and we try to supply a bolt that's long enough to fit the thickest flanges + spacer height. If you find the supplied bolts a little too long, you can add a few washers under the head of the bolt to take up the excess length. Or you can cut the excess length off the end of the bolt after it's installed. Or, we can supply the next size shorter bolts in most cases.

    For un-drilled spacers, you'll want to use the existing flange to mark the spacer for the location of the new bolt holes. The spacer can be clamped to either the drive shaft or transfer case flange, probably easiest to remove the flange from the transfer case output (30mm staked nut holds it in place) and use that, clamping it to the spacer so it does not move. Select a drill bit that just fits inside the bolt hole or use a transfer punch to mark the hole locations. If you are unsure of your drilling skills, you may elect to mark and drill one hole at a time and then use that freshly drilled hole and a bolt to secure the spacer to the flange for marking and drilling the next hole. Once the hole location is marked, remove the flange and drill out that hole (a drill press works best to ensure a straight hole). Use a bit that is as big as or slightly larger than the hole in the flange. Once all 4 holes are drilled, make sure all 4 bolts fit into the flange, spacer and drive shaft before proceeding. If you find a slight misalignment, you can run your drill bit through the holes to open them up a little bit if needed. For the standard 10mm bolts, you generally want to drill the holes with a 10.5mm bit or a 13/32" or 27/64" drill bit.

    Once all 4 bolts are in place, alternately snug them down in a crisscross pattern. Once all 4 nuts are snugged down, torque the nuts to the factory specifications listed in the Factory Service Manual. Lacking that information, you can use approx. 40-45 ft.lbs. (10mm) or 50-60 ft.lbs. (11mm hardware). Be sure to re-check the torque after 50-100 miles of driving. While nylon lock nuts are used with the spacers, you might get a flake of paint or dirt between the shaft and spacer during installation and the bolts will feel tight at that point. But after a while driving, that flake will get crushed and fall apart leaving a tiny gap that can lead to looseness.

    The Ford, Dodge and Chevy driveshaft flanges have internally threaded holes into which the bolts fasten. For those, you can apply some thread locking compound if desired. Photos of replacement, stock length bolts often show a red thread locking compound pre-applied.

    Some bolt torque specifications:

    Toyota 10mm:      54 ft-lb (74 N-m) 
    Toyota 11mm:      58 ft-lb (79 N-m) 
    Ford 12mm:        70 ft-lb (95 N-m) 
    Dodge/Ford 7/16": 58 ft-lb (79 N-m) 
    

    A note on the bolt finish:

    With high strength bolts, you commonly see either black oxide or the blue coating instead of the more common zinc plating. These costings have minimal affect on the dimensional tolerance of the fastener compared to zinc plating. One downside of these finishes is that they don't have the rust prevention characteristics of zinc plating. Black oxide fasteners use an oil or wax film applied periodically to protect the finish from rust. Another option is to apply paint to the exposed parts of the fasteners. This is best done after the bolts are installed since the wrench or socket will likely damage any paint applied to the head of the bolt prior to installation.

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    [Last updated: 01.August.2024 ]

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