** '03 PreRunner --> 4x4 SAS! **

[Revivalist]

** MOST RECENT PICS OF THE RIG **


** This thread has been edited to show "before" and "after" pics . . .

Well, I decided to overhaul my 2003 Tacoma PreRunner and turn it into a rig that can perform a little better off-road. Here’s the plan in a nutshell:

IFS --> Solid axle (with front e-locker)
2WD --> 4WD
No T-case --> Dual T-cases
4.11 gears in back --> 5.29 gears front and back
Stock height --> 5” spring lift
Stock wheels --> 37” MT/Rs
No armor --> Sliders, bumpers, and a winch!

Here’s some pics of the stock rig I picked up in June 06. . .








And here's some pics of the rig in July 08 . . .


[IMG][/IMG]











As for the rest of the story on how this happened, . . . here it goes . . .

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So I’ve done lots and lots of research to figure out what the best options are. So far, here are the parts I already have . . .

1. Custom IFS Eliminator Kit



It’s “custom” because some of the components were removed that won’t work with my 03 Tacoma since the whole kit is made for a 79-85 Pickup or 4Runner. The parts I got are the following:

• 5" Springs – Front
• Front Spring Hanger
• Shackles Front Offset 5"
• Steering Stabilizer Kit
• Shock Hoops, 14"
• Bilstein 5125 14" Shocks
• Bumpstop Extensions
• Bumpstops
• Motor Mount Plates

2. Rear Lift Kit



• 5" Springs – Rear
• Welded Spring Hangers
• Rear Shackle Mounts
• Shackles Rear Wide 5"
• Bilstein 5125 12" Shocks
• Lower Shock Mounts
• U-bolt Flip Kit Rear
• Brake Line, Individual Rear F-M
• Three Hole Spring Perches
• Greasable Spring Bolts & Bushings

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Ok, so here are the parts that I know I still need to obtain:

-- For 4WD Conversion --
• 4x4 Transmission
• Stock T-case
• Second T-case
• T-case mount
• Dual transfer case crossmember
• Floor shift plate
• 4WD shifter boots (exterior and interior)
• Interior plastics
• Speed sensor (if 4WD transmission doesn’t come with one)

-- For SAS --
• Front Axle (FJ80)
• Hub assembly (if it doesn’t come with axle) (new or junkyard)
• New brakes and caliper (if the ones on axle can’t be used)
• Studs for wheel mount
• 5.29 gears (front and back)
• E-Locker
• Rear drive shaft
• Front drive shaft (brand new, lengthened 10” spline, balanced): $260 (Bentup.com)
• 37” mud terrain tires (that fit 16x8 rims)


I’ll be doing getting the work done this weekend with AJ from bentup.com. We already found an FJ80 full assembly, however the seller wanted $1100 for it. Is that a reasonable price? . . . . Also, we still need to figure out what we need to do for steering drag links on it.

Thanks for any tips or suggestions from anyone!

[rockota]

Lots of pics, please. I'm very curious to see how that 29" on center spring width works out on the shackle end...

[ovrrdrive]

Wow that takes balls... Gonna be a great project though. Keep the pics coming.

[GA86yota]

damn...thats all i got to say..but keep the pics coming

[Bones]

Going with a manual or auto tranny? Did you consider keeping what you have and divorcing an Atlas off the back?

Damn I would like to do something like this to mine, but never will have the balls or the $$ to.

BTW, the truck as it is looks great IMO and I would consider purchasing the lift you have now if the price is right.

Good luck

[Revivalist]

Thanks guys! . . . Yes, I will definitely take as many pics as I can. AJ at bentup.com is super-cool. He said it would be fine to take pics through the process and even get my hands dirty a bit.

@ Bones - I was thinking I would keep the tranny auto since that's what it is right now. (Plus, I heard that changing it could cause some issues with smog testing for some reason.) . . .

Yes, it was suggested to me by a local guy to possibly run the divorced Atlas on the back but when we called in it turned out that they don't have the appropriate adaptor. So I pretty much have to swap the tranny. . . .

I'm definitely going to be selling the current lift on it. Look me up again once my IFS is chopped off.

[Pietro]

I wonder if you can still keep your tranny the way it is and just change the output shaft around

Your trans is very similar to the one used in a Jeep XJ, the AW4. The back half looks identical when you remove the tailhousing adapter on either trans.

Maybe someone knows a way to put a different output shaft in yours and then just use the jeep trans to tcase adapter, that way you can bolt the atlas right up to it. Novak-adapters maybe

Good luck on the build

[Bones]

Keep me posted is all. I may or may not want to mess with it. Mine has 3.90's I think and 33's would kill it on the highway is all.

[pr0ject42]

Yo dood, is that a V6 or an I4?

If it is a V6, get yourself a bellhousing from an 88-95 V6 R150 and get an R151 tranny, then slap the typical 23 spline dual t-cases in there and you're done! That will put your T-case output on the right side (passenger side) to do the FJ-80 axle you want.

If it is an I4, just get an R151 and the bellhousing on it will mate up to your engine. Or I guess if you're on the cheap, get any W56 out of an 84-95 I4 and you can do a 21 spline dual case setup..

Speaking of, what are your plans for high-steer on that axle?

You're going to have a dope truck! You plan on putting the same bling rims on it as the bent up truck?

[Revivalist]

Hey, thanks for the great info! . . .

I’ve got the V6. . . Are you suggesting picking up the bell housing and tranny separate? I thought they would basically come together. . . . Also, as far as running dual cases, are you talking about running dual stock cases? . . . I figured that if I run dual cases then I might as get a Marlin Crawler so I can get some really low gears. . . .

For steering, I heard that I can just use the tie rods and steering arms that are already on the FJ80. I also have the IFS Steering Box 86-88, drilled and tapped for hydro assisted steering. . . . The only thing I need to figure out is the drag links. Any ideas? . . .

Thanks again for the help!

[rockota]

If you want to go 5-speed, I agree with finding the 151 if you can. You'll need the early 150 bellhousing to make it work, not the 151, since you have the V6. Likely the better bet is the 150 from a Tacoma, then a Marlin 150-4cyl tcase adapter followed by either a second 4-cyl tcase if you choose the FJ80 axle or a taco-tcase if you go another route.

Personally, and this is just me, I'd skip the Fj80 axle and go Diamond housing or Dana 44. Prices are very similar and you'll have an easier time with the steering on the Diamond or Dana 44.

[Bones]

Originally Posted by rockota

Personally, and this is just me, I'd skip the Fj80 axle and go Diamond housing or Dana 44. Prices are very similar and you'll have an easier time with the steering on the Diamond or Dana 44.

I do agree. Diamond if you have the 3rd, longs and all that jazz. Wash if you are starting from scratch (Toy vs. D44). Steering on an FJ axle is a lot different and aftermarket support is little and $$.

[Revivalist]

Well, the reason I wanted to go with the FJ80 is because it's a 30 spline so it already has the strength to run 37" wheels without having to put down another $1000 in birfields, outer shafts, etc. . .

The FJ80 can also run the e-locker which saves me another $300-$400 setting up an ARB. And unlike the ARB, if the activating mechanism ever fails, you can just pull off the little shield on the diff and lock it with a screwdriver. With the ARB, if something happens to the hose, compressor, etc. . .. then no more locking.

Lastly, I like the idea of getting the high pinion diff (1991+) for a better drive line angle. . . .

[Bones]

You can run an elocker in a regular toyota housing. I'd still rather have an ARB

[rockota]

Originally Posted by Bones

You can run an elocker in a regular toyota housing. I'd still rather have an ARB

Or a diamond housing. I see the point about the HP, but the rest of the comments, IMHO, don't fit. Keep in mind that those 80 axles are full time, so you'll likely want to replace those birfs anyway, which are much more spendy than regular mini truck birfs. And I'm still not sure how you're going tomake the steering work effectively; the steering arms are under the knuckles w/ the tie rod in the back relatively low. You can get around this with (as mentioned) OTT arms, but I'm not sure they are still made or if OTT will machine your knuckles to work. The overall point being, don't rule out an easier/cheaper/stronger solution. Call Brian @ Diamond; I'm sure he'll have some great info. Or talk to the folks at Bent-up as well about their recommended solutions. Since you want to keep the budget low, there might be other options.

Either way, I'm really looking forward to this build!!!

[pr0ject42]

Yeah dood, I'm going to third the opinions here. I've got an FJ-80 axle in my garage and I'm really hung on what to do with it (except sell it to one of you monkeys here )

Get a diamond housing at the width you want set up to take a HP E-locker and use mini knuckles. I'm betting cost-wise it will all come out as a wash as FJ-80 e-locker axles aren't cheap to begin with. Currently there isn't a company that offers a high steer option for the FJ-80 axle. I think Slee offroad might be working on something but OTT quit doing their solution. If you left it as is, you would have to booty-fab up a Z draglink. No thanks.

Also, what I was saying about the bellhousing and trannys is that you might have to buy the tranny, take the bellhousing off and use it, or a bone yard might just sell the bellhousing. Search on car-part.com and call around. IF you are going to go the R-151 route (turbo 5 speed from 86-87 pickup) you will HAVE to get the bellhousing from an 88-95 V6 truck or 4runner (that was mated to a 3.0L V6) because if you get one from a 3.4L V6, the bellhousing is going to be too deep for the input shaft on the R151.

Then get your Marlin stuff and be stoaked! Good luck homes, I hope you've got good credit

[Revivalist]

You guys have some very good points, especially about the steering and the overall cost. . . . I'll ask Marlin and Aj if they recommend that I change the plan around. The only thing that's committing me to the FJ-80 at this point is that Marlin was gonna setup the Dual Ultimate Crawler with passenger side drive line and get it to me by the end of the day. We'll have to change that to driver side if we revert back to a Dana (or I assume for a Diamond also). . . .

Thanks for the input guys! . . . This is exactly what I needed!

Oh yeah, and as for the tranny . . . . Marlin already helped me to hunt down a 3.4L V6 Auto from a 2000 4Runner. As I heard before, he mentioned that going to a manual will cause problems with smog.

[rockota]

Keep in mind that you can still go dual cases/marlin ultimate w/ the driver's side drop as well. Diamond can make whatever housing you need, so if you want to go pass-side drop, Brian can do that.

[Bones]

You can get a dana passenger side drop, and a Diamond is custom, get it where ever you want the 3rd.

I honestly think you need to do a lot more reserch before spending $$ and having people chop into your rig and building you cases.

[Revivalist]

Well, running a driver's side drop would actually be easier because I can be sure not to have issues with the exhaust. With the FJ-80 I may have to reroute the exhaust a bit because it's on the passenger side . . . So if I went with a custom axle then I'd rather just go driver side and ask Marlin to do a left side Ultimate Crawler . . .

Yes, I agree plenty of research has to happen before doing a project like this. I have actually done as much as I can from searching all the forums. Now I'm just working out the details by asking questions on all the forums. Plus, I know that Marlin and Aj are the best out there. . . . So I trust that they'll help steer me right. I think it's really a matter of personal choices at this point. We know what will work and what won't. The question is only what will be the most cost effective.

[Bones]

Originally Posted by Revivalist

The question is only what will be the most cost effective.

Stop this project now then

[rockota]

Originally Posted by Bones

Stop this project now then

That's just mean.... true, but mean...

[MT4Runner]

Originally Posted by Revivalist

I have actually done as much as I can from searching all the forums. ....The question is only what will be the most cost effective.

You're not done researching until you can build the entire thing in your head. If you can build the entire thing in your head, then you have no more questions.

You bet, Marlin won't steer you wrong, but you're wasting your money and his time if you change your mind later.

I'm with Bones. If you're still trying to decide what is most cost-effective, stop spending money IMMEDIATELY!!

[Revivalist]

Thank you for the suggestion guys. . . . I respect that some of you may have a difference in opinion. I hope it's not offensive to you, but after addressing the issues you brought up with Marlin and Aj, I concluded that we can still go forward with this project . . . Basically, here are the pros and cons of a Dana44 versus an FJ80 . . .

Pros of Dana44
-- Easily found, usually cheaper, and can be upgraded with chromoly shafts/birfields . . .
-- Left hand drive line to avoid exhaust
-- Steering can be more easily setup

Pros of FJ-80
-- High pinion diff (without custom work)
-- E-locker can be used (cheapest manually engaged solution)
-- 5.29 gears can be used front and back (instead of 5.13 in front for Dana)
-- Stronger stock axle (30 spline) so no upgrade needed
-- I already have one ready to go coming right off the cruiser, hub to hub
-- "Coolness factor":: most SASs on Tacos have Danas. It's nice to have something different.

Basically, it's still very possible to set it up, and at the end of the day, it's not really going to be more costly. So we're still going to go that way. . . .

[Revivalist]

So yesteday I had a great time at Marlin Crawler getting the tranny and Crawler. . . It's amazing how incredibly helpful and friendly Marlin is! . . . . He found a tranny that we expect should do the job. It's a 4x4 V6 Auto off a 2000 4Runner with 50,000 miles. . . . After lots of inspection at TAP, it seemed that it should work. (Of course, we'll only know for sure once it's in. . . .)

Here's Marlin getting the tail housing preped up for the Crawler . . .





He serviced the tranny right in the back of my truck. . . .








Meanwhile, Rocky getting the Dual Ultimate Crawler ready . . .








And here's me stouting my new toy!





In addition, I picked up the following:
• T-case mounts (2)
• Dual transfer case crossmember
• Twin stick shifter
• Speed sensor kit

I also ran by the Toyota dealer and picked up a T100 2WD oil pan, strainer, and gasket which give better clearance for the front driveline. . . .I'll add more pics of this stuff later. . . .