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John's super slow 3rd gen 4Runner rebuild/build |
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J CROSS 
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Joined: 09 December 2004 Location: United States Status: Offline Points: 631 |
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 Topic: John's super slow 3rd gen 4Runner rebuild/buildPosted: 12 October 2009 at 1:52pm |
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Started with this:
 1999 4Runner, 2wd, 3.4 v6, auto. Killed in head-on collision.
Rebuild/build specs: Replace frame, damaged body panels, damaged engine compartment components. Front: SAS with 80 series Land Cruiser axle and coils 3 link with panhard Ballistic Fab adjustable coil buckets IFS steering box Rear: 80 series Land Cruiser axle and coils 4 link with panhard Engine: 3.4 liter 5VZ-FE Transmission: 80 series Land Cruiser A343F & transfer case running Slee Offroad part time 4 wheel drive kit and manual hubs Tiptronic type manual transmission shift control and a whole bunch of other stuff I haven't figured out yet  Edited by J CROSS - 14 June 2010 at 5:16am |
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"The significant problems we face cannot be solved by the level of thinking that created them" Einstein
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50Willys
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RCRC Vice President Joined: 16 February 2004 Location: Trinity, AL Status: Offline Points: 2916 |
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Posted: 12 October 2009 at 1:54pm |
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John, we need more pictures.
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Bob S.
'96 Cherokee, 4.0L w/Auto Trans & locked D44s '99 Dodge 2500 CTD Tow Rig |
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J CROSS
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Joined: 09 December 2004 Location: United States Status: Offline Points: 631 |
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Posted: 12 October 2009 at 1:58pm |
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Swapping out the old frame for the new      Edited by J CROSS - 25 February 2010 at 12:01am |
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"The significant problems we face cannot be solved by the level of thinking that created them" Einstein
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J CROSS
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Joined: 09 December 2004 Location: United States Status: Offline Points: 631 |
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Posted: 12 October 2009 at 2:03pm |
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Fitting the new wheel well and core support
   Edited by J CROSS - 25 February 2010 at 12:59am |
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"The significant problems we face cannot be solved by the level of thinking that created them" Einstein
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J CROSS
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Joined: 09 December 2004 Location: United States Status: Offline Points: 631 |
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Posted: 12 October 2009 at 2:08pm |
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After seam sealer, primer and paint. I searched and searched but could not find a really good match on the engine compartment paint.
  More to come Edited by J CROSS - 26 February 2010 at 10:44am |
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"The significant problems we face cannot be solved by the level of thinking that created them" Einstein
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bluetoy
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Joined: 17 February 2004 Location: Skyline, Jackson County Status: Offline Points: 2222 |
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Posted: 12 October 2009 at 3:51pm |
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That's gonna be a nice ride when you're done. Those 3rd gen runners are plush.
Progress looks great. Hurry up.
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TOYOTA FOUR WHEEL DRIVE................need I say more?
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50Willys
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RCRC Vice President Joined: 16 February 2004 Location: Trinity, AL Status: Offline Points: 2916 |
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Posted: 13 October 2009 at 1:15am |
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Looking good!!
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Bob S.
'96 Cherokee, 4.0L w/Auto Trans & locked D44s '99 Dodge 2500 CTD Tow Rig |
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phatdaddy
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Joined: 12 September 2009 Location: toney Status: Offline Points: 96 |
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Posted: 13 October 2009 at 1:21am |
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looks like its gonna be a nice ride
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03 TJ 4inch frame lift 35x12.5
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J CROSS
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Joined: 09 December 2004 Location: United States Status: Offline Points: 631 |
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Posted: 14 October 2009 at 2:24pm |
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Your basic frame plating, instead of plugging all the factory holes in the frame I just cut mine to match so the space between the frame and the plate would be sealed.
    Edited by J CROSS - 23 February 2010 at 2:42pm |
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"The significant problems we face cannot be solved by the level of thinking that created them" Einstein
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J CROSS
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Joined: 09 December 2004 Location: United States Status: Offline Points: 631 |
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Posted: 14 October 2009 at 2:30pm |
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IFS steering box, frame is sleeved with 3/8" stainless pipe
  Edited by J CROSS - 28 August 2010 at 3:20am |
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"The significant problems we face cannot be solved by the level of thinking that created them" Einstein
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J CROSS
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Joined: 09 December 2004 Location: United States Status: Offline Points: 631 |
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Posted: 14 October 2009 at 2:32pm |
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Coil buckets tacked in place
  Edited by J CROSS - 08 March 2010 at 2:44pm |
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"The significant problems we face cannot be solved by the level of thinking that created them" Einstein
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J CROSS
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Posted: 14 October 2009 at 2:47pm |
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My first attempt at building links.
Lower links: I used 1-1/4" Johnny Joints (18mm thru hole) at the frame, custom sleeves with cruiser bushings (18mm thru hole) at the axle, 1-1/4" ladder bar adjuster for fine tuning and a custom square insert 6" long drilled and tapped 1-1/4" left hand thread 4" deep. Tubing is 2x2x1/4" wall.     Edited by J CROSS - 28 February 2010 at 2:27am |
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"The significant problems we face cannot be solved by the level of thinking that created them" Einstein
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83K10
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Joined: 17 February 2004 Location: Huntsville, AL Status: Offline Points: 3174 |
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Posted: 15 October 2009 at 11:33am |
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Looks great! I'm glad to see you making some progress. Keep it up.
John |
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J CROSS
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Posted: 15 October 2009 at 3:58pm |
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Thanks everyone, I think I may be seeing some light at the end of the tunnel. It's been two years in the making but I think I will actually start to make some real progress soon.
Working seven days a week kinda slows me down. |
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"The significant problems we face cannot be solved by the level of thinking that created them" Einstein
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J CROSS
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Posted: 26 February 2010 at 8:42am |
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Finally some progress!
Lower links, not finished with the frame mounts.
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"The significant problems we face cannot be solved by the level of thinking that created them" Einstein
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J CROSS
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Posted: 26 February 2010 at 8:44am |
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Coil spring stuff.
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"The significant problems we face cannot be solved by the level of thinking that created them" Einstein
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J CROSS
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Posted: 26 February 2010 at 8:47am |
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Got the engine back in and found the DS engine mount is bent about an inch.
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"The significant problems we face cannot be solved by the level of thinking that created them" Einstein
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alabamatoy
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I dont work here anymore... Joined: 16 February 2004 Location: Signal Mountain Status: Offline Points: 9369 |
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Posted: 26 February 2010 at 10:15am |
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Its always something! Lookin mighty good, John.
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"If you didnt buy your 1st gen 4Runner new, then YOU are a newbie!!"
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J CROSS
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Posted: 26 February 2010 at 11:26am |
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Thanks Doc, I hope to get on the trails with all you good folks someday.
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"The significant problems we face cannot be solved by the level of thinking that created them" Einstein
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bluetoy
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Joined: 17 February 2004 Location: Skyline, Jackson County Status: Offline Points: 2222 |
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Posted: 26 February 2010 at 2:46pm |
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Hurry up already ! I'm ready to see that thing on the trail. Man, I'm not used to seeing all these nice bling parts and fancy brackets welded to a toyota. Looks much better than my pieced together, junkyard leftover, scrap metal.
I'm gonna push my forgotton piece of a 4runner back in the shop next week and begin working on it agian. Maybe I'll finish it before I get sidetracked on 10 other projects this time.
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TOYOTA FOUR WHEEL DRIVE................need I say more?
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J CROSS
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Posted: 26 February 2010 at 4:59pm |
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I had intended on making all the brackets myself, but considering what they cost versus the time it would take I decided to go bling |
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"The significant problems we face cannot be solved by the level of thinking that created them" Einstein
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J CROSS
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Posted: 28 February 2010 at 2:26am |
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Upper link:
I used 1-1/4" Johnny Joints (18mm thru hole) at the frame, custom sleeves with a cruiser bushing (18mm thru hole) at the axle, Ballistic Fab 1-1/4-12 righthand chromoly insert. Tubing is 1-3/4" OD x .120" wall DOM.  Edited by J CROSS - 28 February 2010 at 2:28am |
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"The significant problems we face cannot be solved by the level of thinking that created them" Einstein
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J CROSS
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Posted: 08 March 2010 at 2:03pm |
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Picked this up today and now I got a rear to match my front
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97 Land Cruiser
70,000 miles
full floater
disk brakes
9 1/2" ring gear
63 1/2" wms to wms
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"The significant problems we face cannot be solved by the level of thinking that created them" Einstein
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bluetoy
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Joined: 17 February 2004 Location: Skyline, Jackson County Status: Offline Points: 2222 |
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Posted: 08 March 2010 at 4:12pm |
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Nice rear end ! That's a nice find. You gonna keep the link suspension on it?
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TOYOTA FOUR WHEEL DRIVE................need I say more?
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J CROSS
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Posted: 08 March 2010 at 11:47pm |
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I'm going to try to use the links, since they came with the axle, they are a lot beefier than the 4runner links. There's not much room to work with due to the gas tank but I have seen people relocate the gas tank to the back using a ford tank where the spare tire goes.
I got my hands full just trying to get the front to work  .
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"The significant problems we face cannot be solved by the level of thinking that created them" Einstein
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J CROSS
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Posted: 13 March 2010 at 12:21pm |
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Well I got my upper link tacked in place. I ended up with about 5" of separation at the frame and about 6" at the axle. My next step will be to fit the panhard.
On a side note, I learned to weld 30 years ago, stick and tig and recently mig. I must say at times I hate mig welding, dealing with the torch and heavy hose in tight places under the truck
 is something I am having a hard time getting used to. Oh and another thing, I can't daydream like I used to when stick welding, you have to pay attention the whole time, rant over.      Edited by J CROSS - 13 March 2010 at 12:36pm |
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"The significant problems we face cannot be solved by the level of thinking that created them" Einstein
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Case
RCRC LLC Member
Have you seen my 9/16" socket? Joined: 20 September 2004 Location: United States Status: Offline Points: 1773 |
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Posted: 14 March 2010 at 1:57pm |
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i applaud your choice in square tubed lowers
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06 Jeep Wrangler Rubicon Unlimited all torn apart.
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bluetoy
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Joined: 17 February 2004 Location: Skyline, Jackson County Status: Offline Points: 2222 |
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Posted: 14 March 2010 at 3:16pm |
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I agree. That should be very strong. I wonder why you don't see more people using the square tubeing on lower links ? Any disadvantages over round DOM ?
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TOYOTA FOUR WHEEL DRIVE................need I say more?
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J CROSS
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Posted: 14 March 2010 at 3:16pm |
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"The significant problems we face cannot be solved by the level of thinking that created them" Einstein
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Case
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Have you seen my 9/16" socket? Joined: 20 September 2004 Location: United States Status: Offline Points: 1773 |
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Posted: 14 March 2010 at 3:21pm |
snobbery. The price of suitable round DOM vs square tube was ridiculous. I'll stick with square until someone shows me definitively otherwise. |
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06 Jeep Wrangler Rubicon Unlimited all torn apart.
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Case wrote: