Spindle Gusset Installation Instructions

This weld-on gusset kit is designed to reinforce the factory spindles on 2nd Gen Toyota Tacomas—from the upper ball joint mount down to the lower. Whether you're running oversized tires, long-travel suspension, or pushing your rig hard off-road, this kit delivers the critical strength you need to prevent spindle failure and maintain alignment.

✅ Read the entire instructions before starting the installation.

BEFORE YOU BEGIN

✅ Confirm all kit components are present (see packing slip).

✅ Park the vehicle on a flat, level surface to ensure safe disassembly and reinstallation.

✅ Disconnect the vehicle battery before welding.Disconnect both the positive and negative terminals and secure them safely out of the way.

✅ Read through the entire guide before starting the installation.

IMPORTANT REMINDERS

⚠️ This is a structural reinforcement kit—professional welding is required.

⚠️ Always wear proper PPE including gloves, helmet, long sleeves, and eye protection.

⚠️ Keep a fire extinguisher on hand during cutting and welding.

⚠️ Clean all weld areas down to bare metal before tack welding.

⚠️ AUse Caution when welding near ABS sensor surfaces or machined bearing contact points.

⚠️ Allow welded spindles to cool slowly to prevent warping or stress cracking.

⚠️ Schedule a professional alignment after installation.

TOOLS & SUPPLIES NEEDED

• Floor jack and jack stands

• Basic hand tools (sockets, wrenches, breaker bar, etc.)

• Angle grinder with flap disc and cutoff wheel

• Wire wheel or wire brush

• MIG welder (.030" or .035" wire recommended)

• Brake cleaner or degreaser

• Torch (for preheating cast steel)

• Welding blankets (x2, for cooling spindles post-weld)

• Rivet gun (for SFW logo badge installation)

• PPE: safety glasses, gloves, welding helmet

• Paint or powder coat

Recommended coating:Rust-Oleum 15-Minute High Performance Enamel Flat Black – durable, fast-drying, and a close match to OEM finish.

STEP-BY-STEP INSTALLATION INSTRUCTIONS

STEP 1: REMOVE THE SPINDLE FROM THE VEHICLE

• Chock the rear wheels and lift the front of the truck.

• Support the vehicle with jack stands and remove the front wheels.

• Remove hubcap, cotter pin, spindle nut retainer, and axle nut.

• Unbolt the brake caliper and hang it out of the way (do not let it hang from the brake line).

• Remove rotor, dust shield, and the hub/bearing assembly (access 4 bolts from behind).

• Disconnect tie rod end, upper ball joint, and unbolt lower ball joint (2 x 19mm bolts).

• Remove the ABS sensor and carefully remove the dust seal.

• Pull the spindle off the truck and set it on a clean work surface.

STEP 2: CLEAN AND PREP THE SPINDLE FOR WELDING

• Use a wire wheel to clean the entire spindle of all grease, grime, and rust.

• Wipe down with brake cleaner.

• Lay out all gusset plates on the spindle and trace contact points with a marker.

• Clean all traced weld zones with a flap disc down to bare metal.

• ⚠️ All weld surfaces must be bare and free of contaminants for proper weld penetration.

STEP 3: TEST FIT THE GUSSETS

• Mock up each gusset to check for proper contour and fit.

• Grind casting lines or irregularities if gussets do not sit flush.

• Ensure gusset holes for brake lines and sway bar tabs align with spindle holes.

• Minor trimming may be necessary—each spindle casting can vary slightly.

STEP 4: TACK WELD GUSSETS TO THE SPINDLE

• Lightly bolt on the brake line tab to aid alignment.

• Insert the 3D printed shim into the circle bore where the dust sewal used to be. This shim help set and maintain proper spacing for cv axle clearance while tacking.

• Preheat the spindle with a torch to draw out moisture and reduce thermal shock.

• Confirm final fitment and alignment.

• Place multiple tack welds around the gussets to secure them in place.

• Recheck all clearances before continuing.

STEP 5: FULLY WELD THE GUSSETS

• Inspect all tack welds and confirm gusset contact.

• For large gaps or uneven contours, lay a root pass first before final welding.

• Begin welding the internal seams and spindle-to-gusset contact areas.

• Avoid welding near the machined bearing face or ABS sensor surface.

• Break apart the laser-cut interlocking tabs and install them—these self-align with the main gusset.

• Weld remaining gussets in alternating areas to distribute heat evenly and prevent warping.

STEP 6: COOL AND CLEAN THE SPINDLE

• Wrap the entire spindle in a welding blanket and let it cool slowly for 4–5 hours.

• Once cool, wire wheel any surface discoloration or oxidation.

• Clean again with brake cleaner.

• Apply 2–3 light coats of paint or powder coat as desired.

STEP 7: INSTALL THE SFW LOGO BADGE

• Once painted, rivet the SFW badge onto the gusset using the provided rivets.

• Be sure to install the correct badge on the correct spindle—badges are side-specific.

• Check alignment and install with a rivet gun for a clean, professional finish.

STEP 8: REINSTALL THE SPINDLE ONTO THE VEHICLE

• Bolt the spindle back into place: – Torque lower ball joint, upper ball joint, and tie rod end hardware to spec. – Use new cotter pins for all castle nuts.

• Reinstall the hub assembly, rotor, ABS sensor, axle nut, and spindle retainer (with new cotter pin).

• Use the supplied allen head bolts for the upper brake caliper bolts (tight clearance near gusset).

• Reuse the factory lower caliper bolts.

• Secure the ABS wire using one push-pin zip tie per side into the hole on each gusset.

• Reinstall wheels and torque to spec.

STEP 9: FINAL TORQUE AND FUNCTION CHECK

• Torque all fasteners to factory spec one final time.

• Spin the hub to ensure there is no interference.

• Double-check all cotter pins, hardware, and gusset clearance.

• Inspect all welds and paint for full coverage and adhesion.

STEP 10: POST-INSTALLATION AND ALIGNMENT

✅ Reconnect the battery.

✅ Clean up the work area and verify all tools and hardware are accounted for.

✅ After 100 miles of driving, inspect: 

– All welds for signs of stress 

– All hardware for tightness 

– ABS wire routing for secure attachment