Brojohanson Build Thread

Well it was a long time coming but I finally got the supercharger installed! Still need to source a boost gauge and install the meth kit but as a stand alone install the truck has quite a bit more power. Mainly noticing the torque gains. Going to give it 500 mile break in with the JonBondPerformance rebuild before really getting into it.

 

Moved to California and figured now is a good of time as ever to go through with a 4x4 + 5 speed swap. Snagged a barn find 04 with all the factory options, and only 100k on the clock. Had been sitting for 8 years and in Toyota fashion, still runs and drives with nothing more than fresh oil and gas! Some interior water and rat damage from sitting but truly is a testament to Toyota quality. Perfect candidate for parts if you ask me with the decade of past due CA registration looming over it. Hoping to get started on disassembly over Thanksgiving break. Will have quite a bit of parts hitting the for sale forum soon!

 

dibs on the front end. Let me know how much once you start taking it apart. Looking to get fenders, hood, bumper, headlights etc

And all 4 flares.

 

Have the parts truck mostly pulled apart. Got the Engine/Transmission/Transfer case out all in one go. Had to cut the radiator support. Odd that they are welded and not bolted in. Now onto the rear diff then ship the rest off to the junk yard.

 

Instead of sending to the junk yard figured I'd go all the way with it and strip it down to the frame. I know these frames are problematic so thought it would be good put this one up for sale and help someone revive their truck. Had a guy come want to buy just the cab so this worked out great.

FYI, For anyone removing their cab off the frame, we snuck the Spare Tire under the trans tunnel, then grabbed on that with the engine crane through the cab.

 

Worked on cleaning up the 5 speed and rear E-locker before it goes into the truck this weekend. Wire wheeled the entire transmission + rear end housing and got the transmission painted. E-locker portion is next but wanted to inspect the gear set first. Looks fine, gonna leave as is and drop into the truck once it is repainted. Grabbed some of the Eastwood Rust Encapsulator for the diff.

Transmission:


Rear End:

 

Xmas 4x4 + 5MT underway! Lots of parts I've been hoarding going in.

 

Did you sell the silver doors you had for sale?

 

Doors are gone. Only things left are frame Bed and fender flares. Also have the knuckles.

 

Wire wheeled + painted the pedal assemblies. They were crusty when i pulled them out of the truck. Not looking too bad now. Will add some grease to the moving parts and toss them into the truck.

 

New fluids all around for everything coming off the truck. Supercharger doesn't have very many miles since rebuild but figured it could use some new fluid as well.

 

New AISIN clutch kit + hydraulics. Using LUK flywheel, have seen mixed reviews online but had good luck in a Jetta we've had before. Will see how it holds up in the truck.

 

Transmission before going in.

 

Had to mangle the rear main seal to get it out. No damage to the crank surprisingly given the old seals condition after it was removed.

 

Had to make some modifications to the cat in order to fit the DT headers. Shot of everything in the truck.

 

Needed some motivation to finish. Getting close!

 

New Clutch Master Cylinder going in. Went with OEM AISIN.

 

Shifters and T case in. Will need to heat and bend the J shift handle. Interferes a bit with reverse/4hi and lo. Going to live with it for now.

 

Maybe I'm just missing context but I've done an auto to manual swap and remember having to source a different t-case handle because the auto one went a weird direction.

 

You remember which T case handle you used? I took the handle apart and flipped it 180 degrees so it turns out the opposite way, but still wasn't enough room to clear. I've seen people cut/weld or heat/bend to make the stock one work.