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Malek's 02 DC 4x4 - L3X0TA - 1UZFE + Manual Swap

Discussion in '1st Gen. Builds (1995-2004)' started by Malek, Jan 22, 2017.

  1. May 26, 2020 at 7:55 AM
    #21
    Malek

    Malek [OP] Well-Known Member

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    1UZFE VVTi 5spd Swap
    Thanks man! I don't think I could go back to a naturally aspirated auto 5vz at this point.

    The 96-97 front end on your dc is looking really damn good!
     
    Ccrowe323[QUOTED] likes this.
  2. May 26, 2020 at 8:54 AM
    #22
    Ccrowe323

    Ccrowe323 Well-Known Member

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    Haha thanks dude, hopefully I can get it painted soon.
    How do you like your RTT? I’ve been wanting to get one but I haven’t heard much from actual owners of different brands. Everyone has something to say about what brand they choose and why.
     
  3. May 26, 2020 at 9:13 AM
    #23
    Malek

    Malek [OP] Well-Known Member

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    1UZFE VVTi 5spd Swap
    I've never liked sleeping on the ground so even though it was cramped, I always slept in the bed of the truck. I'm 5'5" so it was never too much of an issue for me but it became less ideal for longer trips with more equipment. But why I specifically went with Hutch, well, they had the best deal going on at the time I was ready to buy. I was waiting for a deal on Tepui but they never dropped, understandably. I know I wanted a telescoping ladder and the thought of dropping bank on a tent and then immediately modifying it to swap out ladders wasn't appealing so I didn't even look at those that came with collapsible ladders. And then I knew the smallest size is still a lot more room than what I was used to and could also fit under the softtopper so it became an easy choice for me (I think it was the only one under 1k with a telescoping ladder at the time). I've been out 5 times so far and I haven't had any issues at all with it. The skylights are an absolute game changer for me on those clear nights with bright stars!
     
    Ccrowe323[QUOTED] likes this.
  4. May 26, 2020 at 9:50 AM
    #24
    Ccrowe323

    Ccrowe323 Well-Known Member

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    Same here Would rather not sleep on the ground, I’ve been looking into cot/tent setups but the ease of a rtt is nice and the skylights would be a huge reason for me to buy a specific brand over another. And for the price the hutch seems like a good deal compared to smitty built or others in the price range.

    Also just noticed you’re in the panhandle, I’m in Florida too, down on the east coast. Glad to see someone else from Florida that knows how to build a rig that isn’t just for mudding lol thats pretty much all that’s around me
     
    Last edited: May 26, 2020
    Malek[QUOTED][OP] likes this.
  5. May 30, 2020 at 8:19 AM
    #25
    Madjik_Man

    Madjik_Man The Rembrandt of Rattle Can

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    @Malek

    Ever dream of hanging out in Colorado with a potentially future new best friend who will feed you great food, drown you with great beer/whiskey/Scotch and who just so happens to have a 2004 DC with a shoddy auto transmission....who also thinks is the best solution is to do a R150F swap onto his 3.4 but finds it out of his league to do?

    I’m just sayin...
     
    Malek[OP] likes this.
  6. Jun 2, 2020 at 10:02 AM
    #26
    Malek

    Malek [OP] Well-Known Member

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    1UZFE VVTi 5spd Swap
    Ah man, you're just a few years too late! I lived in Golden 2011-2015.

    However, the dream still stands of moving back to CO!
     
  7. Jun 6, 2020 at 3:47 PM
    #27
    Malek

    Malek [OP] Well-Known Member

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    1UZFE VVTi 5spd Swap
    Storm Cristobal is keeping me from camping this weekend so here's an update instead.

    ARB On-board Air setup from Wheelers was delivered this past week so I went to work on that.

    On factory manual trucks, this would be the clutch start cancel button. But mine was a factory auto so it had the Electronically Controlled Transmission switch...well, seeing as I don't need that option anymore I chose to put the compressor switch in it's place. A few swipes with a file and it was a perfect fit.
    [​IMG]

    Since my cruise control never worked, I decided to take it out and use the bracket for the compressor. Two of the existing holes lined up and already had grommets so I used those and drilled 2 new ones and used a similar thickness rubber sheet to match the grommet offset. I'm not sure I'm happy with the orientation of the compressor. I originally wanted the front angled towards the front of the truck but the carriage bolts were a pita to line up so I didn't feel like taking it apart again once I realized my mistake. But now those two empty holes make it seem so out of place. Ugh, I'll experiment with it another day.

    Also, instead of ripping off all the tape and flipping the harness so the ARB fuse is by the battery I took the easy way out and just installed another one. I guess ARB does this as maybe they assume compressors will be installed by the batter anyway and most of the wire will be trimmed? Not sure.

    Compressor mounted as well as using a factory hole on the firewall shelf to mount the fuse
    [​IMG]


    Some of the wire routing along the firewall
    [​IMG]
     
    Last edited: Dec 28, 2024
  8. Jun 20, 2020 at 5:11 PM
    #28
    Malek

    Malek [OP] Well-Known Member

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    1UZFE VVTi 5spd Swap
    Haven't done much with the bike mount yet but I did get some new taco meat (more on that later).

    A few pics from last weekend, pre-meat:
    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]

    Yeah, yeah...I realized on this trip that those dumb bars for the top cover are removable.
    [​IMG]

    ARB Compressor worked perfectly
    [​IMG]


    And on to the meat of this post: 4Runner 5star wheels with brand new 285/75r16 Pro Comp Xtreme MT2s. Surprisingly, they fit without spacers BUT there is about a quarter of an inch clearance between the tires and UCAs. So yes, spacers are on order from Wheeler's.
    [​IMG]
    [​IMG]
    [​IMG]

    Here's a better picture with the Softtopper folded forward. I took the RTT and bars out to put the wheels and tires in the bed and I am SO glad I went through the extra effort of making separate mount brackets for the RTT bed bars. 8 bolts total and the bars are off without needing to take the topper off.
    [​IMG]

    I think I'm going to end up painting the wheels with Rustoleum's Soft Flat Iron spray paint. Thanks to @ImpulsedComa with his post giving a nice visual reference: Spray paint wheel color options...


    Here's a very poorly done photoshop attempt courtesy of snapchat scissors but it gives a good idea:
    [​IMG]

    What's TW think for the new wheels? Leave them silver, that dark grey color, or fuck-it-flat-black?
     
    Last edited: Dec 28, 2024
    Flare side Taco Lover likes this.
  9. Jun 20, 2020 at 11:17 PM
    #29
    Madjik_Man

    Madjik_Man The Rembrandt of Rattle Can

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    My vote is for "FIFB" because I have the same truck, same wheels and am about to paint them and want to see what it'll look like :oops:

    For real though I'll probably go VHT Satin Black as that's what I did my 98 wheels with. But my 98 is Sunfire Red Pearl, so the look is completely different. I've had black wheels on all my vehicles since 1991... never dawned on me to do another color. But I have to admit that Soft Flat Iron with the Lunar Mist looks amazing.

    My only concern would be the lug nuts. The stock silver would stand out on the graphite and black lugs would look wonky.
     
    Malek[QUOTED][OP] likes this.
  10. Jun 29, 2020 at 2:34 PM
    #30
    Malek

    Malek [OP] Well-Known Member

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    1UZFE VVTi 5spd Swap
    Finally fabbed up a brake proportioning valve lift bracket...as can be seen in this photo:
    [​IMG]

    And some more photos from the weekend's run:
    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]


    (Click for Video) And the sketchiest of water crossing's I've done so far pulled from my dashcam. 1st puddle, not so bad but that 2nd one had me sweating. No audio so what you don't hear is the engine revving and wheels spinning swampy water everywhere. Gotta love Florida.
    [​IMG]
     
    Last edited: Dec 28, 2024
  11. Jun 29, 2020 at 2:57 PM
    #31
    Madjik_Man

    Madjik_Man The Rembrandt of Rattle Can

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    Your fender flare (and photo lighting) is so faded it looks color matched :oops:

    I love your truck. Inspirational for the 04 DC I just picked up.
     
  12. Jun 29, 2020 at 3:01 PM
    #32
    Madjik_Man

    Madjik_Man The Rembrandt of Rattle Can

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    Even without audio that slow down, bog down in the second puddle was enough to give a sinking (no pun intended) feeling.

    God, I hate mud.
     
  13. Jun 30, 2020 at 10:55 AM
    #33
    Malek

    Malek [OP] Well-Known Member

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    1UZFE VVTi 5spd Swap
    Welp, looks like that can and a half of flat black spray paint is going to my fenders now :bananadead: haha thanks man!

    You're telling me! I need a winch big time if I'm going to keep playing in the muddles, which means I'll need bumper...and a snorkel probably wouldn't be a bad idea.

    And the mod list goes on lol
     
    Madjik_Man[QUOTED] likes this.
  14. Sep 12, 2020 at 9:18 AM
    #34
    Malek

    Malek [OP] Well-Known Member

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    1UZFE VVTi 5spd Swap
    I did the thing:

    [​IMG]

    What a pain and a half that was to fit but she's on there now! Things would have been about 10,000% easier if the Badlands Apex winch was clockable but it was pretty obviously made to be mounted feet down on a Jeep bumper instead of feet forward inside an ARB. The engage/disengage selector interferes with the AC Condenser crossbeam so I cut the selector and notched the crossbeam. There is still a little interference but nothing crazy. Will just have to winch out instead of free spool.

    I also picked up an aFe Dry Filter and 1st edition WaterPort on the marketplace. Wasn't necessarily looking for more water storage but the price was right so I figured why not - and camp showers are nice.
     
    Last edited: Dec 28, 2024
  15. Sep 13, 2020 at 2:03 PM
    #35
    Malek

    Malek [OP] Well-Known Member

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    1UZFE VVTi 5spd Swap
    While we’re on the subject, easy mounting solutions for the WaterPort with some Lowe’s hardware.
    [​IMG]

    [​IMG]

    Burn hole right through the carpet. Dang. At least the tank hides it.
    [​IMG]

    [​IMG]
     
    Last edited: Dec 28, 2024
    Dalandser likes this.
  16. Oct 17, 2020 at 9:28 AM
    #36
    Malek

    Malek [OP] Well-Known Member

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    1UZFE VVTi 5spd Swap
    Went out for another solo trip last weekend. The camp shower is a GAME CHANGER. Not sleeping covered in bug spray and dried sweat made for a much nicer night.
    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]
     
    Last edited: Dec 28, 2024
  17. Dec 28, 2024 at 4:10 PM
    #37
    Malek

    Malek [OP] Well-Known Member

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    1UZFE VVTi 5spd Swap
    Wow...it's been 4 years since I've updated this thread.

    Anyways, the truck has a VVT-i 1UZ-FE in it now from a 2000 Lexus LS400. I will try to post as much information as I can here to help others but mostly myself when I need to go back and fix/replace something years down the line. All in all, this was one of the more annoying engine swaps I've done and took about 2 months start to finish working in the evenings and some weekends. Let's get started.

    The donor, a 2000 Lexus LS400 with a fair bit over 200k miles. It had horrendous suspension clunking (forward arms?) but otherwise the engine ran and that was the most important thing to me. I wanted a running donor. The entire swap could have been a lot less complex if I opted for an earlier model LS400 without VVT-i but I don't plan to boost it and figured the VVT-i was a decent compromise for the little extra power.

    [​IMG]

    [​IMG]

    I drove it around for a month or so just to make sure there weren't any hidden engine problems. A few check engine lights for cats/O2 sensors but nothing that worried me. But man was it dirty. Years of oil leaks and built up grime. I did my best to clean it up but I would have needed a year supply of brake parts cleaner and degreaser to get it where I wanted.

    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]

    And then the teardown started in my dungeon. Compression test checked fine so I initially just planned to clean it up, gaskets, water pump, and timing belt. One thing led to another and I pulled the heads off.

    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]

    My best friend from college (and the reason I sped ran this whole project) said he'd be in town over thanksgiving and was keen on swapping a V8 into a Tacoma. So we pulled the 5VZ out that weekend and dropped in a Lexus V8.

    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]

    It's a tight fit...but it fits!

    [​IMG]

    [​IMG]

    Header/steering shaft interference solution is not pretty for now but it works and doesn't leak.
    [​IMG]

    And finally, first start video (pre-exhaust)!
    [​IMG]

    Technical Info:

    Engine:
    Gasket and Water Pump kit:
    I ordered this gasket and water pump kit from Mizumo Auto. It was certainly a hodge podge of random gaskets that mostly fit the VVT-i but there were obviously some that were non-VVTi. It was fine.

    Oil Pan:
    The LS400 has a front sump oil pan which is more* ideal for IFS rigs. I opted to swap in the upper and lower oil pan along with the oil pick up from a 2000 Tundra since it was designed to fit around a front differential. I'm glad I did this because the front sump would not have fit without some serious modification. 2WD trucks can use the front sump all day.
    Tundra Lower Oil Pan P/N: 12102-50111
    Tundra Upper Oil Pan P/N: 12111-50110
    Tundra Oil Pick Up P/N: 15104-50170

    Oil Filter mount:
    The LS400 oil filter points toward the rear of the engine and then puts the oil filter squarely into the driver side frame. You can use a shorty oil filter or a remote mount if you want to use it. The SC400 and Tundra use a forward mount. I found a Tundra oil filter mount without the cooler attached and swapped in the filter bolt. It worked and I'm not certain because they have different part numbers but it seems to be the same as the SC400.
    Tundra P/N: 15609-50110
    SC400 P/N: 15609-50040

    Oil Pump:
    Nearing the end of the rebuild, putting the timing belt on, I go to thread on the timing belt pulley into the original oil pump and pulled the threads straight out all in one piece. It seems whichever shop did the timing belt last did the same thing and instead of telling the customer, they gobbed it up with loc-tite and thread sealer. Looking online, a new OEM oil pump is around 400 dollars. Oof. But, I took a gamble and got one for a 2UZ for 85 dollars. Fits and works great.
    LS400 P/N: 15100-50040
    Tundra P/N: 15100-0F010

    Engine Mounts:
    I reached out to CXRacing about their engine mounts. They could not tell me if they would work on a 4x4 (aka raise it high enough to clear the differential). I ended up taking a gamble and they worked. If I had more time, I think I would have liked to make my own. These are fine but the design makes it impossible to adjust the height without taking them completely out.

    Fuel Delivery:
    The LS400 uses a returnless style fuel delivery system where the FPR is inside the gas tank and the pump has two modes for low and high fuel requirements. This was too complicated and I like simplifying things as much as I can. The 2UZ uses a return style system and has a FPR mounted on their passenger side fuel rail. Well, wouldn't you know, you can flip that sucker around and mount it on the drivers side for an easy return style 1UZ set up. As long as you keep the vacuum line plugged, it will maintain static pressure. I am using the 4.7 FPR for now but once I upgrade the fuel pump, I will use the 5.7 FPR for a higher static pressure that the 1UZ supposedly likes better.
    Tundra Passenger Side Fuel Rail P/N: 23807-0F010

    Power Steering Lines:
    5VZ lines fit. No modification required. However, the LS400 uses a remote reservoir. I was able to bend the mounting brackets on the reservoir and used a mounting hole for the intake box and the cruise control.

    AC Lines:
    Do not fit. 5VZ mounts the compressor on the passenger side. 1UZ on the driver side. I have not addressed this yet.

    Transmission:

    Engine to Transmission Adapter:
    I used the XAT racing adapter plate and flywheel for long shaft R154 using the 1UZ bellhousing. It's machined well and looks great. Plenty of resources online for the steps. It is popular for the community who use 1UZs and Supra transmissions for their drift cars. I do have a small gear oil leak from the transmission to plate side but that may just be my own fault when assembling the two. Not enough gasket maker, etc. Threw in some ARP flywheel bolts for fun. Why not.

    Transmission Mount:
    Because the adapter is a thickboy, it pushed the transmission back about 2.5 inches. I kept the original cross member and welded a 2x3" piece of angle iron to it that I had previously (remember my removable RTT cross bars!)

    Clutch:
    MR2 Turbo. I am using an Exedy OEM spec.

    Throwout Bearing:
    Chevy T56 hydraulic throwout bearing with stainless steel braided lines. Get the bleeder extension, otherwise it would be impossible to bleed with it mounted in the truck.

    Master Cylinder:
    A 3/4" is required for the Chevy throwout bearing. Perfect from a Landcruiser. Aisin CMT-032

    Driveshafts:
    I had to have the rear driveshaft shortened exactly 2.75 inches. And then I used the front driveshaft from the automatic since it is longer. I don't believe this will be an issue and it hasn't been so far but only time (read: trails) will tell.

    Exhaust:

    Headers:
    I used aftermarket steel non-VVTi 2UZ log style headers for a Tundra. The headers from the LS400, though far superior in flow design, simply will not fit between the Tacoma frame rails. The logs barely fit as it is. And this presents the most annoying part of this swap for me. The driver side header flange interferes with the steering shaft. I knew it would but hoped it wouldn't. I ended up cutting off the header flange, extending it down about 5in and using a slip fit for the catalytic converter/downpipe connection. It is not the ideal solution but it works for now and it doesn't leak.

    Catalytic converters:
    I used cats from a 2000 Tundra to fit the headers I am using. The fit well but require cutting the original hangers as they interfere with the frame on both sides.

    Mid-pipe:
    Again, I connected the cat pipes straight to mid-pipe from a 2000 Tundra. Obviously, that connection is perfect and I did not need to modify anything with it. From the mid-pipe, I cut the factory 5VZ muffler pipe after the secondary cat and mated the Tundra mid-pipe to the 5VZ muffler. That really muted the 1UZ. It doesn't sound particularly interesting now but I might come back to this later.


    Wiring:


    Engine Harness:
    I bought some schedule back by sending my harness to Lexusv8.com for them to modify. Tim is incredibly knowledgeable in the world of Lexus V8 swaps and does lightning fast and great work. Extremely responsive to my emails as well. He replaced just about every connector on the original harness because I broke them pulling it off the engine and then sent a test video with my harness and ECU. I opted to have him remove the immobilizer as well.

    Transmission Harness: Separate post here
    In order to have a functional speedometer, 4wd ADD actuator, reverse lights, and the ability to start the engine from the ignition, I needed to build my own transmission harness and incorporate it into the engine harness. I'll come back to this with wiring diagrams and pictures. It was not hard but tracing wires, depinning/repinning plugs, and routing was time consuming.
     
    Last edited: Jan 12, 2025
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  18. Dec 28, 2024 at 6:39 PM
    #38
    Madjik_Man

    Madjik_Man The Rembrandt of Rattle Can

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    Unreal awesomeness.
     
    Malek[OP] likes this.
  19. Dec 29, 2024 at 1:26 AM
    #39
    Yetimetchkangmi

    Yetimetchkangmi Well-Known Member

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    ARB front locker, Custom high clearance rear bumper, Custom plate front bumper, mile marker winch PE8, safari snorkel, Deck Plate Mod Fox 2.5 rr DSC, Camburg UCA, squeaky Dakar leafs, 5125 10" and custom 7.5" shackles, thee finest PNW pinstripes, MT-R, Nissan crew cab roof rack??? wtf is that about??? Allpro skids, Rigid duallys President McKinley CB with PA Recaro SRD with Wedge Engineering Morimoto retrofits Champion Rad - Failed Tundra brakes
    Wait one:

    You swapped a Lexus LS400 V8 AND retained 4wd AND 5 speed manual???!?!?
     
  20. Dec 29, 2024 at 6:54 AM
    #40
    Malek

    Malek [OP] Well-Known Member

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    1UZFE VVTi 5spd Swap
    Yessir!

    I did the 5 speed swap years ago with the 5VZ. Had I gone with an older 1UZ I probably would have went back to auto because they use the same A340 a 2WD Tacoma uses so a tailhousing swap from a A340F to mate the transfer case is easy work. The VVT-i uses a completely different 5 speed auto A650 with no easy way to mate it to a transfer case. So, path of least resistance to retain 4wd was keeping the manual lol
     

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