MattJakob's 'Everything but a Tacoma' Thread

That wrenching bug is starting to itch again...
Here's a few photos from this weekend/tonight's progress. I was sort of stopped as far as I could get since I didn't have a 54mm axle socket but one was delivered today so I finished pulling apart the driver side knuckle assembly this evening. I'll get the driver side done this weekend, drop the housing off Monday for welding, and pick it up sometime mid week.
I'm hoping by the end of next weekend, I've got the axle back under it, brakes working, and ready for some engine work.

Untitled by Matthew Jakobowski, on Flickr

Untitled by Matthew Jakobowski, on Flickr

 

Got the axle prepped for a truss, knuckle gussets, and diff guard. I'll drop it off for welding tomorrow and it should be done later this week.
I also started tearing down the axle I picked up last week. I wasn't able to fully tear the axle down as the previous owner decided it was a good idea to use RTV between the free wheel hub assembly and the IFS hubs. I tried cutting out what RTV I could, and using a BFH, but I couldn't get the cone washers out and there were no signs of it letting loose. I'll drop the knuckles off at the shop that's doing the welding to see if they have any luck - otherwise, I guess I'm cutting the free wheel hub off.
I was able to remove the whole hub assembly, which gave me the ability to pull the RVC axles.
Hopefully the shop doing the welding can get the knuckles fully disassembled and I'm able to start rebuilding this axle later this week.

One thing I do need to sort is the steering out - I can't run my stock steering with the 6 shooters, and the 85 steering is inferior to other the options available. I'm looking at an IFS box with hi-steer, I just need to decide what box and if I'm doing hydro assist - end goal is to have hydro assist but I need to confirm the rest of the rig is right before proceeding too far.

Untitled by Matthew Jakobowski, on Flickr

Untitled by Matthew Jakobowski, on Flickr

Untitled by Matthew Jakobowski, on Flickr

 

I would hit that free hub body with a lot of heat. It'll come off.
If you have a slide hammer, you could also thread it into one of the holes on the hub body and give it a couple wacks in a couple different spots.

For those cone washers, thread a nut onto the studs, and slam the stud with a brass drift and the cone washers should pop out eventually. They're a pita, but should come out with some persuasion. Also use the drift to hit the body around where the stud is too

 

I was able to get the free hub body off the one's that came on the truck no problem - there's a few instances on the 6 shooter knuckles where the cone washers have RTV seeping out the tops.

I've hit it with quite a bit of heat - no luck.
I've got a slide hammer front hub puller attachment on the way - I'll thread these onto the studs and see if I can pull from those.

I left the knuckle assemblies at home when dropping the axle housing off so I guess we'll figure it out. The slide hammer attachment should be here by the weekend so we'll get after it this weekend. If I've got a fully reassembled axle by the end of the weekend, I'll be happy.
Then onto sorting out the steering

 

Word. That's annoying af. Who the hell thought putting rtv on the cone washers was a good idea

 

I've gotta say - whoever assembled this axle didn't know what they were doing.
Mismatched hardware, the bolts into the calipers were too long and needed to be cut out, trunnion bearing eliminator kit on 3 of the 4 trunnion bearing locations, RTV everywhere, uneven shim packs at steering arm and trunnion bearing caps, incorrect steering preload - the list goes on...

 

Picked the axle up on Wednesday - welds look good and the thing looks much beefier than before the truss + gussets.
I'm hoping to get it under the 4Runner this weekend, and the 4Runner on it's own weight next weekend.
Untitled by Matthew Jakobowski, on Flickr

 

Was able to finally get the knuckle assemblies apart.
In addition to the RTV between the free body hub and the IFS hub, the previous owner also used RTV between the front side of the knuckle and the spindle. With everything apart, I was able to start cleaning the hubs, knuckles, and spindles.
I had to use a mix of heat, a wire wheel, and a razor to get the gaskets + RTV off - but all is clean and almost ready to go together.
The previous owner was also running Trail Gear's trunnion bearing eliminator kit, which I'm opting not to run. I was able to get the steering caps pressed out of the steering arms, but need new caps that will allow me to run trunnion bearings. I'll order new caps and hopefully have them sometime this week, pressed in during the week, and ready to put it all together next weekend. Hopefully.
Untitled by Matthew Jakobowski, on Flickr

Untitled by Matthew Jakobowski, on Flickr

 

I was able to spend a few hours in the garage over the weekend - threw the axle under the 4Runner and finished up some miscellaneous work on the hubs and knuckles.
When taking apart the spare axle I bought for parts, I noticed that the previous owner had mismatched hardware on the knuckles - some of that hardware being ARP studs. I didn't have enough ARP studs (11 take-offs) to use them everywhere, so I mounted 4 ea to the bottom of the knuckles and used OEM studs up top. I'll carry the remaining ARP studs as trail spares, with a couple OEM ones in their too.
I also installed new bearing races into the axle housing for the trunnion bearings and into the hubs for the wheel bearings. New lug nuts were also hammered into the hubs.
I'll be running 1st gen Tundra brakes and needed a bracket to mount the calipers to the knuckle assembly, I picked those up from Front Range Off Road and will get them painted and ready to mount up.

My ladyfriend graduates from Vet school this Friday and her family will be in town through the weekend - so I'm sure I'll be running around doing grad stuff/celebrating.
Following that, she'll be heading out of town for a few weeks on a girls graduation trip so I'm hoping that buys me the time to get this thing on it's own weight.

Untitled by Matthew Jakobowski, on Flickr

 

Started putting everything back together again with the intent of having the 4Runner on its own weight this weekend but was halted for a couple of reasons.
The lower trunnion bearings (new) would not fit over the aftermarket caps for the bottom of the knuckle. The caps don't have any burrs or rough surfaces preventing the bearings from sliding down. Ended up ordering new caps which will be here this week.
Untitled by Matthew Jakobowski, on Flickr

The IFS hubs need to be machined down to work with the brakes I'm planning to run (231mm Tundra brakes). I see a few options are available, going to call a few places and confirm someone can get them to me sometime this week.
Untitled by Matthew Jakobowski, on Flickr

Besides that, everything is actually starting to come together which is a nice sigh of relief.
Untitled by Matthew Jakobowski, on Flickr

 

Spent a couple hours in the garage this evening and got the passenger side front knuckle buttoned up. Hoping I can find a few more hours this week to get the driver side done.
I also ordered a few under the hood items I'm hoping to get installed in the not too distant future.
Untitled by Matthew Jakobowski, on Flickr

 

Was able to get the driver side buttoned up as well, and install my tie rod. I did a makeshift alignment, setting the tie rod to have 1/8" of outward toe. Prior to actually taking this thing out, I'll have it professionally aligned.
I was going to bleed the brakes, but I've ordered new hard lines and will install those prior to bleeding. I'll also install an extended braided rear brake line which will go in prior to the bleed.

I went to mock up the 37s, just to see how it looks when I realized the Aisin hub body won't fit through the center bore of my SCSs... Time for new wheels - I've got a line on some Black Rhino bead locks but I need to confirm I won't run into the same center bore problem.
In the meantime, I've ordered some 3" wheel spacers as the current steel wheels won't clear the bigger Tundra brakes. The wheel spacers will be a temporary thing until I install the new suspension which will clear the 37s.

Current plan of attack is to bleed the brakes, install wheel spacers, and basically get it on it's own weight by July 5th. On either July 5th or 6th, I'll be dropping it off at a shop to install the IFS steering box. I'm hoping to get some of the work done myself (removing old box, mocking up new box, drilling frame, etc.) to make its time at the shop shorter. Once the IFS box is installed, this thing is theoretically drivable again and I'll focus on getting it to pass smog. Once it passes smog, I'll register the thing, then install the suspension, 37s, and all fun things that come after that.

37s look huge, but good.
Untitled by Matthew Jakobowski, on Flickr

 

why don't you just have your wheels bored out to fit the hubs. Cheap

 

I'm actually texting Caleb from HMF right now - didn't think to ask him if he knows of anyone yet.
I called around Sacramento and found a few guys who could do it but none that could do it within the next month or two. Others didn't want to touch it.
I'm not super attached to my current wheels and found a pretty screaming deal on some new bead locks ($350/ea).
We'll see if Caleb has anyone.

 

I'm hoping the next time I update this thread, this thing is on its own weight.

I've got wheel spacers, hard lines for front brakes, and an extended rear brake line on the way - I'll throw these on and bleed the brakes this weekend.
Over the weekend, I ran all new vacuum lines and installed a PCV valve, grommet, and hoses. I also started prepping for the IFS box as I'm dropping the vehicle off on July 5th to have that and a frame mount installed.

My timeline has pretty much gone to shit on this thing but I should have no problem meeting the July 5th drop off date.
Untitled by Matthew Jakobowski, on Flickr
Untitled by Matthew Jakobowski, on Flickr

 

3" wheel spacers worked for getting the current wheels mounted around the bigger brakes. Off to the shop to get the steering box mount welded on.
Untitled by Matthew Jakobowski, on Flickr

 

Bro stance engage

 

Snuck a peek at this machine recently.


PXL_20230706_185733106 by Cory Bechtold, on Flickr

 

Took the 4Runner to a local shop to have the IFS steering box mount welded on. That and the box are now on and upon hooking the lines back up, I noticed they've seen better days. The lines were frayed and leaking where the hose meets the fittings.
I decided to order an upgraded power steering pump kit instead of just running new lines as I'll be running 37s with the intent to run hydro assist once this build is further along.
The kit comes with a new power steering pump and bracket, reservoir and bracket, belt, hoses, fittings, cooler, etc. which will help with supplying the future hydraulic ram with enough power.
It'll be here tomorrow but it'll be hotter than hell over the weekend - hopefully I can find some time every evening to install it.

Untitled by Matthew Jakobowski, on Flickr

 

Another thing done, still a lot of things to go.
Yesterday, I was able to finish up the installation of a new power steering pump and bracket, reservoir and bracket, belt, hoses, and cooler.
Once I finish a few other items, I plan to replace the radiator with an all aluminum radiator and I may move the cooler - I intentionally left some slop in the lines if the cooler does move.

This week, I'm hoping to bleed the power steering, install a new rear brake line + bleed, and do few misc items related to the throttle body. Then hopefully, I'm able to actually drive the thing and see what else it needs before starting with the suspension.

Untitled by Matthew Jakobowski, on Flickr