DIY Frame Replacement

Plus I can sell everything I remove, up to and including the OEM locker switch, for not nothing.

 

fantastic progress this far

 

Moving parts

 

4x4 vs 2x4 transmission mounts

 

New frame is from a prerunner, not sure if I mentioned that. Moved trans mount to new crossmember and reversed it. I read that prerunner crossmember is 1” higher and 1” further back, so I got 1” engine mount spacers on order, and I’m hoping that that and turning the mount backwards is enough offset to line everything up.

 

3rd is getting a TrueTrac installed

 

I’m going to be selling a 4.10 e-locker rear axle assembly complete from drum to drum, minus actuator but including harness and the matching front 3rd if anyone is interested.

 

i dont believe the cross member is different at all i dont remember anyone whos done the 4x4 conversions running into issues.

 

Oh well that makes it easier. They appeared to be the same when I measured.
I read that here https://tctmagazine.net/march-2013/2wd-to-4wd-conversion-part-2
but it’s about 2nd gen, so my mistake.

 

Yea the difference should only be the trans mount itself

 

If only you were closer. I’d be on top of that

 

Why'd you go with a true trac. Thinking of getting one myself

 

On slick roads, an LSD is better than a locker. Different if you’re wheeling, but I do very little “off-road”.

 

Two weeks ago today, after calling the Toyota dealer to see if they could press everything together, I dropped off all my new OEM parts to be assembled in some Prerunner knuckles.
On Saturday the service advisor called to tell me they were the “wrong parts”. They were both convinced you couldn’t replace a 2wd hub with a splined 4wd hub. Then I argued with him and the technician about whether or not the knuckles were the same. I convinced them to “try”.
Called to check status this morning and the advisor, again, says they are the wrong parts. I said which parts EXACTLY are “wrong”? Said I’d best come in as it’s hard to explain on the phone. After taking me to two different techs and insisting the “wrong parts” was the problem, they show me how they broke an ear of the bearing retainer snap ring. (I provided new snap rings, in fact everything in this diagram)
So I take the knuckle home, spend 15 minutes removing the broken snap ring, and then bring back to them. Both techs and the advisor seem genuinely confused.
There were two other first gens on hoists in the back, and I feel bad for them. On the way out I mumbled something about letting me know if they need me to remove the other snap ring.

 

I brought it to the dealer because I don’t have a ton of faith in my local Les Schwab.

 

Still no word from Toyota. Getting started on the frame reinforcement.

 

Donor frame was missing rear cab and front bed mounts, so this is another salvage mission.

 

.

 

This gives me flashback to trying to get my hubs/wheel bearings pressed into my ABS spindles. Didn't even mention a 4WD conversion to my local Toyota dealer and they freaked out when they realized there was an ABS hole in my spindles with manual hub mounting on the hub. They refused the work. Took them to a machine shop that actually somehow bored out the inner bearing surface on one spindle with something splined. The bearing overheated on that side and damaged my caliper and warped my rotor. Lucky I made it back from a Colorado trip with that going on (had my passenger get out to turn their hub and they were far too hot to touch).

So I redid both sides myself borrowing a giant press at my buddy's machine shop. Such an ordeal and part of why I won't get work done anywhere anymore.

 

Passenger side body mount and bed mount welded on, chopped the 3 driver side mounts out of the old frame.