Apologies in advance, another noob 4x4 thread

So before I get flamed to death, let me just say I've done an a55load of searching. I've compiled a good bit of information, but I'm seeing that some of the info repositories are offline, so I'm not getting a clear answer on a question.

First the truck, 2002 ext cab, 2.4l 2wd, 5spd, 93K miles. Just bought it from a buddy for $500. Runs like a top, a bit of cosmetic sheet metal damage, but I can fix all that. I was just curious if a 4wd conversion was even something people do and found it's pretty common.

So I've got a source for the front diff, cv joints, front hubs, basically the whole front end from a guy who is going through an SAS conversion for under $300. This means I still have to source a 4 cylinder transfer case, front/rear drive shafts, rear diff hubs and 6 lug wheels. Did I miss anything here?

I saw links to a PDF that appeared to cover the whole conversion, but I can't find a working link to that anywhere. Does anyone have a good link to this document?

But here's the big question, will the output shaft on the 5 spd transmission have to be swapped to fit a transfer case?

 

Ah, so looking at pics, I see the input shaft for the xfer case is splined. So I'm guessing that's the different type of output shaft I'm gonna need. I think once I get that parts in front of me it's going to make a lot more sense.

 

Your transfer case will bolt up on top of the trans! On the top part of this.

 

Don't have a pic of the inside to show you.....yet.

 

Wait! Does your truck have 5 wheel lugs on each wheel or 6? Your info suggests it is a 5 lugger, as you list the motor size as 2.4L. If true, I don't see how you'll be able to use the 6 lug 4x4 Tacoma parts on your rig.

Are you planning swap to 6 lug spindles in front to accommodate the front diff and axles? Does the 2.4L oil pan clear all of that? This will mean new upper and lower a-arms too. Do they mount to the same place on a 5 lug or are you going to fab new mounts for everything?

 

Yeah, 5 lug wheel hubs. I'm looking at an exploded view of the front end and I see what you are talking about. I think I can get the entire front end, but I'm thinking about another way to get this done. A local guy has a running, driving Taco with just shy of 200K on the odo that he rolled. He's looking to get $1400 for the whole truck. That has me into the truck for about $2K. I can do all the work myself, but I'm starting to wonder if this is going to make any financial sense or not. Looking at used trucks 4x4's are well north of $7K on autotrader and craigslist, so I'm thinking this makes sense.

 

Oh, and the local truck is a factory 4x4. So that will ensure I have all the extra bits, brackets, etc...

 

Please don't try this. You are basicly building an entire different truck. Not much is going to fit. Maybe the logo on the grill. That's about it.

 

If the frame and driveline components of the rolled truck are all in good shape, it might be smarter to mount your 5 lug cab and front clip onto the rolled truck. Its a lot of work but has been done. @Blackdawg

https://www.tacomaworld.com/threads/the-frankenstein-build-lt-expo-trail-rig-and-bs.159436/

 

It can be done its more so a question of whether or not its worth all the time and aggravation.

 

this right here makes the most sense....

 

If you had a prerunner youd be on to something, but trying to convert your 5 lugger will be a chore...

 

Just SAS up front with 63s in the rear with some rock assault axles, and dual cases.

 

There's an idea...

I appreciate all the feedback. Not knowing what I didn't know, I didn't know 2wd prerunner and just 2wd were different. Now knowing that, this would be an enormous PITA.

 

You can not make a 5 lug 2wd into 4wd. It won't work. The front suspension is totally different and won't allow for 4wd at all. Same with the steering rack.

Your best bet is the body swap.