94 4runner build up (needs build name)

[mtnbiker4evr13]

With all the trading and selling on the side of the 4x4 addiction i finally ended up with something that has stuck around for a little bit. Flashback to a couple months ago i ended up trading an ugly running tracker for a non running 94 4runner 3.slow 5spd with the back full of parts. Sadly those didn't include the little sensors and random missing parts from the owner's son swapping engines and just getting it bolted up. Fast forward two months, I have tracked down all the missing engine parts, got it running, got it running well, got the a/c hooked back up and recharged, and threw some 33s under it for my own amusement. At the same time i have been collecting parts for the build up. Thanks to the Frazer brothers for selling me the main parts needed for the build up.

The build list:
SAS with an 84?(full truss) toyota solid axle, ifs hubs, longfield axle shafts, Spartan Locker 5.29 gears
Trail gear high steer
3in trail gear front and rear springs (coil rear suspension delete)
97 4runner rear axle, rear disks, Toyota E-locker, 5.29 gears
Plate front/rear bumpers, rock sliders

Before i start cutting i need to get a few mounts and brackets for the springs another E-locker or lockright and gears
As it sat when brought home
Lots of missing and thrown together parts

Running and driving with some extra shoes I had laying around

Pretty clean for a project

Mall crawling status

[mtnbiker4evr13]

Have all brackets, ubolt kits and everything to hang the axles except time and space to work. Just ordered a spartan locker for the rear axle to hopefully be ready for the trail ride this weekend. Will still be ifs and coil sprung but on 33in xterrains locked in back hopefully. going to weld up some sliders to protect my doorjams
97 3rd gen 4runner rear axle, 84/85 front axle mid teardown with 3in trail gear springs and hanger in the background

4.30 E-locker third

[Creepycrawler]

pics or it doesnt exist lol

[mtnbiker4evr13]

Installed the Spartan in the rear before driving it to Barcamp, it got the 4runner everywhere it needed to. Drove it up to the club's fall picnic at, ran everything it had to at Bishop's and the Frazer homestead with many questioning looks, only a slightly massaged gas tank skid to show. To date it sits with 1in boost in the rear, locked rear, and 33s. Waiting on 6cyl 5.29 gears before I start cutting to keep the downtime to a minimum.

[mtnbiker4evr13]

Just lightened the ol' wallet with a pair of 6cyl 5.29 gears on the way. Have the front axle torn down to a bare housing to install creeper gussets and remove years of neglected muck.

[mtnbiker4evr13]

Yesterday got around to fabbing up some sliders finally, pretty happy with how they turned out. Used 1/8th wall 2in square tubing for the sliders and 1x2in 1/8th wall for the stringers with 1/4in scab plates and long gussets on top of the stringers.



So I took a friend to tar hollow to test out his new lift and tires but didn't get to test the sliders.

[LAR-308]

Passed you on the trail, How did the ride go? Ron

[mtnbiker4evr13]

Went fine other than dodging enduro riders on a couple trails, nothing broke or stuck. Ran all the usual trails, didnt have what it takes for powerline but it was fun trying. Ran what was left of 33/35 but all in all a good day on the trails. Looked like you guys had fun (the grand with no bumper or grill) haha

[LAR-308]

Power line has washed out alot since the last time I was on it. I warned the GC about bumper damage he could expect, I work with him. He left the grill at home. It was a good day, Ron

[mtnbiker4evr13]

Took the runner to Marietta for the October trail ride, didn't need tugged but did have to beat on it to make it through a couple obstacles mainly a mud hole and a wash out. Resulted in a busted tail light and a dent on the rear passenger corner first of many I bet.

[SHAKEnBLAKE]

Wow, looks like some serious mud. That's one of our only "regular" sites I haven't been.

[mtnbiker4evr13]

Yea, bald terrains and red clay don't mix. Update pertaining to the thread, was going to start the IFS and coils this weekend as I claimed Marietta was the last outing for the 4runner set up this way due to tire and clearance issues. But due to problems with my powerjoke i need it for DD duty again. Plans were to try to have the 4runner finished for the December ride at McArthur guess we'll see how it works out.

[mtnbiker4evr13]

My buddy found me another elocker to use and my 5.29s are in. Powerjoke is fixed enough to dd so this weekend the 4runner is seeing the blue flame.

[tef]

That a boy. Just now noticed you had a build thread on the runner. I considered throwing one up for my black zuki. But its slow enough progress as is lol. Glad to see my bro and i's old parts being put to a good home tho

[mtnbiker4evr13]

I figure the lurkers like me would enjoy a build up, plus you dont see too many 2nd gen 4runners getting built up. The parts did go to a home... a good home? thats debatable, but they will be used and abused. I would like to see a buildup of the black zuk its pretty sweet looking as it sits.

[mtnbiker4evr13]

So lately i have been working like a dog to get the runner ready for the december trail ride. I think i have 7 or 8 8hr days in the solid axle swap and rear leaf swap.
Started with the torch cutting all the ifs parts out


Cut frame tubes and tacked on the front spring hanger


Hung springs to check clearance issues, started wondering how tall this beast is going to be... rear is stock height.

Started torching the rear(just as much if not more work than the front)

Sitting on springs with no shackles

with 6in shackles to level out front to rear

Started elocker mods on the front axle


So in the past week i moved the front axle back an inch and a half, this corrected steering geometry issues and brought the wheel back into the wheel well an acceptable amount. Did the final install of both axles and did the modifications to use IFS hubs on the solid axle. Wired up the lockers and both work and drove it around for a few days to break in the gears before this weekend. Just got in from the garage mounting shocks front and rear and re-installed the rear bumper to keep the law happy. Tomorrow i will cut down a drive shaft and re-drill the front output on the tcase for the driveshaft. Also my new tires should be in tomorrow! 35x12.50x15 Goodyear MTR's wrapped around some 15x10 eaton beadlocks

[mtnbiker4evr13]

Took the runner on the McAurthur xmas ride. All went well and was able to walk almost all the lines I took, never needed the strap and it was comfy. Selectable lockers are awesome for a long wheelbase vehicle and mtrs rock even in mud. Did have some things come up that need attention, first off the tires need more room to move, The front tires were biting into the rear of the fenderwell and firewall. The front driveshaft vibrated badly when load was applied, I think a late night brain fart was to blame with out of phase yokes. The tire room has also been remedied as I moved the axle an inch and a half forward today. The steering still looks like it clears with only minor contact at full stuff between the tierod and draglink. With that move I do need to re-tube the driveshaft or get another one to cut down.

[mtnbiker4evr13]

Figure an 8ish year update is required on things. It maybe stayed untouched for about a year after the initial build, I fought front driveshaft vibrations since I was running a standard single joint shaft made from a 3rd gen 4runner front shaft. Also the slip was too short for a reverse shackle setup so it would drop a shaft when really twisted up. Coincidentally the 4runner turned out to be super capable so I made the jump to dual cases after the first Stillwell trip adapting from the 3.0 5 speed to a pair of gear drive cases using Inchworm clockable adapters and 23 spline inputs throughout while they were still in business.

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Beadlocks were pulled since they were not round and aluminum 15x8 Alcoas thrown on and the runner could drive hours away, wheel, and drive home on basically every trip for a long time. Oddly they survived 3-4psi beat downs under a 4500lb+ rig without popping a bead.. ever!

Broke a few axles so the OG longfields from the Samurai were swapped over. Blew up a worn longfield at Heiney farms doing 6500rpm up "left turn" trail I think. Blew up a rear R&P at Still well going up the waterfall under similar circumstances but drove it 3hrs home

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After smashing up the front I hastily threw a winch on it before the Slade trip in 2015 I think

It ran all over Ohio, Slade, Harlan, many trips to Stillwell, Daily drove for 30k miles and all in all has been the best vehicle I have ever owned.

Unfortunately we are at the sad part of the fairy tale. General mistreatment, deferred maintenance and sitting(in Ohio) for 3ish years have been very unkind. I pulled the MTRs and sold them before they were useless with dry rot planning its jump to 37s or 40s. Body/frame rust are getting bad as well as a general raisin appearance from trail clearance-ing. I have had to chase mice out several times and need to again after nesting around the AC Evaporator. Que sad rock ballad music. But all is not lost, after getting to NC on the farm I finally put a new battery in it(for some reason it eats batteries when sitting for 2 years...) and fixed the busted brake line so she's moving again!

now to plan the next build phase: Truggy the back half to keep up with the Jones' and remove the worst of rust and damage? re-build on a fresh frame/body and start at square 1 (probably best with kiddos) or throw all the parts on a Goatbuilt or JHF chassis for a toyota buggy?

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Fortunately the ol' girl will never be for sale so its future with me will always exist.

[mtnbiker4evr13]

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I did a thing... rust free rolling chassis from SC.

Edit... Tan 4runner will be a parallel path. I don't have enough self control for a straight solid axle runner again haha. Probably will be a "Fauxverlander"

[mtnbiker4evr13]

Jump to 37s is in progress. Local place had a set of used 37x12.50x17 Milestar Patagonia MT's for a reasonable price. 60ish% tread. Decidedly not my favorite tread pattern and who knows on compound for slick rocks but cheap 37s are hard to pass up. Plus since I am not emotionally attached to them they can be grooved to my heart's content.

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This winter I'll leave the tail end of the runner alone in case I need it for anything but need to get 17in wheels, fix lights, replace bushings and remove traces of rodent nests through the interior and dash.

Spring time will be Chop time. Plan to cut after the rear seat to make a "crew cab", push the rear window forward so the roof line remains the same and I don't like when people put the truck rear window on runners. Probably 4link the rear and make a little "Utilerai" style bed for firewood, chainsaws etc.

[mtnbiker4evr13]

17in steelies and TMI DIY Beadlock rings ordered so hopefully it'll be rolling on the new tires in January.

And stumbled on a good deal on 16in air shocks. Ugly BUT these are Ballistic (crap) branded ADS (good) shocks. They used the same idea Sway-A-Way did with an oversized body and shaft, I think its a 2.125" shock with a 1.375" shaft to hold weight better. Better yet, they way they sit I can drive by braille and not worry about scratching up baller shocks...



Took a stab at link geometry but there are some assumptions I don't know if I will be able to package. Frame height is low, will have to relocate gas tank etc. But I like the lower Anti-Squat %, Slight understeer for better tracking at speed and I got the roll axis up to maybe keep it stable on side hills. Tried the least frame side lower triangulation possible so I didn't have to build a crossmember around driveshaft issues. Link placement hopefully will allow a small bed in the back for utility stuff, need to figure out gas tank situation though.

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Pinion change at bump 6in up travel is under 4%, Roll axis increases for more side to side stability

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Pinion Change at Droop is under 7% 10in droop, Roll axis doesn't fall off too bad

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Anyway its a start.

[JLockert]

Looking good ...........well sounds good

[mtnbiker4evr13]

Double post... oops

[mtnbiker4evr13]

Thanks Jim. Slow progress but still progress..

Wheels! Now to just grind, weld and hopefully leave them round-ish.

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Have been using the runner as a chariot around the property. 3.slow still cranks right up. Bald 31s are terrible!
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Also if you live in the same valley as a ski resort, there might be something to consider..
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[ernie]

I never do it but I am a fan of keeping your junk useable. It helps you justify keeping it going

[mtnbiker4evr13]

Yeah originally all the toyota crawler goodies were to go under the gold 4runner to basically remake my green one as a straight clean trail rig on 35s.

Then the green chassis would be scrapped to become Walmart frying pans or truggy it on tons and 40s for 4 door crawler that would likely never come to fruition.

So now we'll see where it goes but I'm aiming at gold one being the mild camping rig I intended to build the first go around and the green one can continue being toyota 4 door crawler.

[mtnbiker4evr13]

Got impatient on adding beadlocks with a ride coming up in January so the 37s were mounted up.

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Have some clearancing to do on rear of sliders and other places but it drives pretty well. Looks way better!

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Compared to stock haha. For 37s its actually pretty low all things considered.

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[mtnbiker4evr13]

January trip changed for us with weather. Decided to stay close and head to Harlan Ky for a shakedown solo run. This was the first trip for my son in the 4runner and the first time it had been out for 3ish years. Snows from the previous week were still around from Lower Rock Garden on up to the top of the mountain. Rail bed is way worse than it used to be, I had nothing for the top end of it.

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The Patagonias actually did decent here, aired down to 6/7psi and with temps in the mid 30s still grabbed rocks. Still wouldn't buy them new... but for round rubber things they work for now.

UTVs had iced up the trails so we kept to the lower sections until I broke a side gear in my rear axle leaving 3wd. After that we found green trails to run and explore the areas of the park we usually skip on summer trips. It was actually pretty cool to just drive around... and stop every 30mins or so to pick icicles or break ice on puddles, throw snow balls etc... the 5 year old fun things.

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So some repairs are needed, which is exactly why a shakedown was needed. Tires rub more than I thought which bound up the rear tire and popped the side gear. Front axle has had a bad habit of breaking knuckle studs and it loosened up again. Front shock mounts have always been a quick less than ideal setup so its finally time to make real hoops after the 10th breakage.

Ran into a group of 5 "value enhanced" Cherokees while parked on a trail and they summed up something we all know pretty well.

Cherokee guy 1- "You wheeling by yourself?"
Me- "Yeah, just putting around the easy trails."
Cherokee guy 1- "I'd never do that... you must trust your rig more than I do mine..."
Cherokee guy 2- Wispers to his buddy "Well... its a Toyota..."

I didn't have the heart to tell them I was still cruising on broken parts on my first trip after it sat for 3 years.

[JLockert]

Looks fun

[mtnbiker4evr13]

In the name of Toyota Tech:

Early (88-90) V6 side gears are Toyota Part Number 41331-35040 which 8in elockers (low and high pinion) use on the non actuator side. This can only be bought in a $300-500 kit of all the side/spider gears. Used to be $60 individually new but NLA individually.


Later (90+) V6 side gears are Toyota Part Number 41331-35011, same as FJ80 High pinion, Tacoma, 4runner etc. without locker also 4cyl diffs 85+. Also NLA individually in the states but can find sellers outside US.

So what do you do?
41039-34060 Spider/Side gear kit from Toyota can be found in Dubai... for a couple hundred bucks and has the near impossible to find actuator side gear with splines so ill have a backup. Pretty steep for diff gears but is cheaper than another elocker. I have a spare but its earmarked for the Goldrunner.

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Oh well, can't complain with 10 years of abuse in the 4runner topping 4500lbs with dual cases and many rev limit bounces up obstacles. Can't say I'm not tempted by the 5.14 geared 1 ton rear axle sitting in the barn however...