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Discussion Starter #1 (Edited)
Hey guys,

I had this log on another board and I have been more active myself on pirate so I thought I'd post it here too.

Quick story: I had a 06 Tacoma which I sold in 2013 when I moved as I needed something with good mph for the crazy commute I had at the time. I bought this 90' pickup extended cab in fairly decent condition a year later with the intention of doing a SAS. Within a month of owning the 90' I ended up changing the clutch, cat and tires. Loved these 33's but ended up regearing with 529's to be "future proof", as it turns out it worked out nicely. I pretty much did nothing to the truck for a few years until I moved back closer to work in 2017.0

Anyway, not much was done between 2014 and 2016:




Upgrades done:
* BFG MT's 33x10.5R15
* New clutch
* New cat
* 529's 8" front/rear
* Harrop E-locker front/rear
* 4" HD SAS w/ Slag Factory hanger
* Longfield 30-spline Chromo birfield's
* Dual Tcase 2.28 / 4.70 - new cross member
* Custom/Modded triple stick
* 4" springs in the rear
* Camper shell

Things in progress:
* front driveshafts here, need new superflex joint
* fabricating custom tire carrier for TG rear bumper

Things plan on doing next:
* chromo rear axle shafts - received
* chromo front hubs inner/outer - received
* new tires, still debating - probably 37's
* diesel swap
* sliders

Log:
* 09/30/2014: Installed BFG MT's 33x10.5R15
* 10/16/2014: Replaced clutch
* 07/10/2015: Replaced radiator (3-row full aluminum)
* 08/12/2015: Installed Yakima roof rack and basket
* 09/27/2015: Replaced spark plugs, checked gap
* 09/27/2015: Replaced spark plugs wires
* 09/28/2015: Played with idle screw. Affects RPM but still runs low when cold
* 10/03/2015: Adjusted timing back to stock (10 Degree) but it seems the truck is running worse that way
* 10/04/2015: Found a vacuum leak in the break booster (internal), found one at a junkyard and will replace it soon
* 10/04/2015: Checked ECT and resistance checks out
* 10/11/2015: MAF sensor cleaned up and dead after reinstall, engine won't start. Start but stalls when MAF is unplugged
* 10/11/2015: No error code reported by the computer
* 10/18/2015: CSI is sprinkling when cold and trying to start the engine
* 10/25/2015: Reman MAF installed and works. Replaced Air Cleaner, old one had a hole in the bottom of it; probably reason of some of the problems
* 10/25/2015: Replaced the O2 sensor
* 10/25/2015: Measured vacuum ~ 12 in.Hg with leaking brake booster installed
* 10/25/2015: Timing moved back to roughly 15-degree
* 10/30/2015: Replaced the ECT
* 11/01/2015: Cleaned up the TB and checked the TPS
* 11/01/2015: Replaced the Brake Booster, and measured vacuum again ~ 14 in.Hg
* 11/08/2015: Oil change. Replaced oil filter
* 11/14/2015: Replaced oil pressure sending unit
* 11/14/2015: Replaced the EGR valve
* 11/14/2015: Replaced most vacuum lines
* 11/15/2015: Replaced some parts of the intake
* 11/15/2015: Checked the ECT resistance on the ECU side (THW-E2) and it measured ok
* 3/21/2016: Passed SMOG with flying colors
* 4/13/2016: Tire rotation alignment - front was pretty off
* 4/14/2016: Trail Gear front bumper
* 4/20/2016: Replaced catalytic converter
* 5/14/2016: Cleaned injectors w/ Red Line SI-1
* 6/25/2016: Replaced the ECT again, and also replaced the ECT connector
* 7/2/2016: Replaced the TVV
* 7/10/2016: Removed rear third member (456's) and shipped it to Zuk
* 7/12/2016: Removed front third member (456's) and shipped it to Zuk
* 7/16/2016: Picked up both front and rear third (with Harrop E-locker) from Zuk's (thank you again!)
* 7/17/2016: Installed new rear third (529's)
* 8/21/2016: Put the new front third (529's) back together
* 8/28/2016: Front third back in the truck
* 8/28/2016: Breather mod (front and rear)
* 9/11/2016: Put some break-in miles (200 done, 300 to go...) on those 529's and I'm just loving them
* 9/24/2016: Bought a 83' solid front axle which came with pretty much everything including manual Aisin hubs, diff with 529's and Detroit locker
* 9/12/2018: Started rebuilding that 83' solid front axle. Replaced cap and rotor, added refrigerant, oil change on rear diff. and air filter cleaning
* 9/27/2018: Finished cleaning up the 83' axle, knuckles. Cut off brackets. Painted the axle. Installed bearing races in the hubs
* 10/3/2018: Welded passenger side 3/8" leveling plate and axle gusset. Rebuilt knuckles and started adjusting bearing preload
* 10/12/2018: Welded front diff armor
* 11/5/2018: Finished rebuilding knuckles, adjusted preload, installed the new locked diff and 30-spline Longfield front axles
* 12/27/2018:Installed hubs and locking hubs
* 4/16/2019: IFS out of the truck!
* 4/30/2019: Cut IFS brackets off the frame
* 5/7/2019: Installed and tacked front hanger, cut shackle holes, welded shackles tube, installed leaf springs and suspended the front axle
* 5/23/2019: Installed wheel spacers, tires, put load on the spring, finished welding front hanger, installed shocks and welded hoops
* 6/6/2019: Installed steering
* 6/11/2019: Took rear axle out, cut perches out, tack welded new ones, welded new rear hangers, installed springs
* 6/18/2019: Disassembled the rear RF1A to prep. for 4.7 gears
* 6/29/2019: Started reassembly of rear RF1A
* 7/3/2019: Finished rebuilding the rear RF1A with 4.7 gears, added front RF1A with 2.8 gears
* 7/25/2019: Trimmed center consoled, installed the 2 Tcase's in the truck
* 9/18/2019: Re-Installed rear axle, finished welding spring brackets and shock brackets
* 10/1/2019: Installed dual Tcase crossmember, brake lines, E-brake
* 10/12/2019: Fabricated new brackets for triple stick install
* 10/22/2019: Installed rear driveshaft, camper shell, drove it around
* 10/27/2019: Started fabricating tire carrier for TG rear bumper - first side done
* 11/3/2019: Continued fabricating tire carrier - second side done
 

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Discussion Starter #4
Diff rebuilt with 529's and e-locker. Rear RF1A Tcase (rebuilt with 4.70's later) and front Tcase



Front axle rebuild continued:




 

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Discussion Starter #8
Rear Tcase rebuild w/ 4.7 gears. Other than some trouble getting one difficult snap ring and a missing C-clip with the 4.7 kit it was pretty straight forward. I should be done with it on Tuesday when I'll receive that C clip:



 

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Discussion Starter #9
The rear suspension is pretty much done at this point, we just need the Tcases installed to set the rear diff pinion angle right:





 

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Discussion Starter #11
Aww give these springs a chance to settle haha the shacke angle is nowhere near where it will be once it settles.
And really all the pics here are with only the front done and stock rear, so the whole front of the truck is looking up pretty badly.
 

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Discussion Starter #12
Finished rebuilding the rear Tcase and bolted on the front one.
2.28 front, 4.7 rear.
23 splines on both and both top shift.

Still need to install the R150 transmission adapter plate for these gear driven Tcases. (my 90' is a V6 and has one of those early chain driven Tcase which I will be listing in the classifieds soon)





 

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Discussion Starter #13
We pulled original 90' V6 Tcase (for sale!), trimmed the center console and installed the dual Tcase setup. For now the cross member isn't back on (missing 2 sets of Tcase mounts), but the dual are resting on a jack and the tranny is strapped in anyway.




foto upload
 

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Discussion Starter #14
Found out I ordered the wrong dual Tcase cross member =/

Finished with the rear, although the shock length seems way off (maybe 3" left of compression travel) when using the 12" shock that came with the kit, original shock mount location on the frame and bracket welded on the side of the axle (front on driver side/rear on passenger side). Something's not right.

I aimed the rear diff toward the rear Tcase flange to get my angle right, so I can finally measure that and get drive shafts made.

 

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Discussion Starter #15
I picked up the right cross member which I'll probably install this week.

I'm still debating what to do tire wise. I don't mind doing some trimming to fit 37's but I'm not sold on it. I am somewhat disappointed with the amount of lift gained from the 4" springs front and rear (especially on the front). It will probably settle after a while though.

Whether it's 35 or 37, I'll probably go with 12.5" wide tire which is the most common in those sizes. What kind of wheel backspacing should I go with? When I put those 33's on years ago, I really didn't pay much attention to wheel backspacing, and I think the backspacing on them is a lot less than stock (no way of checking since the front axle is from a SAS). Also the SAS kit came with 1.5" spacers so that the front width matches the rear. Not a big fan of spacers to begin with and for that reason I think going with a wheel backspacing closer to the stock value probably makes the most sense.

If anyone has any input selecting the right wheel backspacing would help! at this point I'd be more inclined with not increasing the overall width, which would equate to increase wheel backspacing by 2" since the new tires will be 2" wider.


Cheers
 

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Get rid of those springs. If you’re going to use this to go to Dairy Queen, then don’t cut anything and run 35s. If you are really going to wheel, cut to fit 37s.

You have a lot of reading to do, up top in the Bible.
 

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Discussion Starter #17 (Edited)
Thank you for you help.


We installed the cross member. 3 of the frame threads will need to be retapped.


We're also kind of struggling to get the Tcase shifters not to interfere with the 5spd shifter. I'm using a triple stick kit from RD and we had to shorten the threaded rods connecting to the rear Tcase so that when pushed all the way forward the 5spd shifter doesn't hit anything. It's less than ideal because now once pulled all the way back the Tcase shifters are basically 30degree off the horizontal. Hmm


 

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Discussion Starter #18 (Edited)
on the shifter interference: I ended up shortening the 2 levers that came with the Rad-Design kit, bending the shifter in the front Tcase in a "S" shape, and remaking the bracket/flange that came with the Rad-Design kit. Doing that allows to relocate the 3 sticks roughly 3" back, away from the 5spd shifter.

I haven't shortened and installed the turnbuckle connecting rods, but it looks like it should work nicely.









 

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Discussion Starter #19
Rear driveshaft came in and was installed yesterday. Drove the truck around, everything sounded and felt right.

Also installed the camper shell I found on craigslist a while back.

I really wish I went with 3" springs instead (front and rear). Hopefully everything will settle down an 1" or so. The idea was to put 35's anyway, but considering I don't have 35's yet and the chromo axles up front (rear chromo not installed yet) maybe I should go with 37's. It doesn't even look like any trimming will be needed. Either way I'll go with 17x9 wheels w/ 4.5" backspace instead of the 15x8 w/ 3.5" backspace I have right now.


how much settling should I expect from these 4" springs? (HD front).



 
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