PreRunner 4x4 Conversion Journey Thread

Thanks Jason! That's good to know, hopefully I can track a couple down. This is the 90080-30028 one you mean right?

 

Correct

 

Sweet thanks man

 

A ridiculous battle with the A.D.D. Intermediate shaft today as I tried to swap in a manual diff tube. It’s held in with a similar C-clip that holds your CV into the diff, and I had the same trouble as Timmy the toolman did in his vid. Thing would not budge. I don’t understand all the posts just being like yeah use a screwdriver to lever it out. I made a custom slide hammer jaw, tried suspending the diff from the intermediate shaft and hammering the body down, and every variation of prying I could. In the end I had to open up the clamshell, and then it was just a few easy taps from above to get it out…infuriating. Well, at least I was able to confirm it’s got 4.10 gearing, and I’m able to thoroughly clean the innards/shell more easily. Any reason I can’t give the main gear cluster a brake cleaner bath?

 

When I did my 4x4 conversion the plan was to slap a manual tube on but was not able to get that shaft out. I tried numerous times and with different approach and just couldnt get it out. I finally decided to just roll with the hose clamp mod. Glad you were able to get it out

 

That was definitely my original plan too but I figured what the heck if I’m only doing this once I might as well go all in lol. But yeah it’s nearly impossible without disassembling the shell I feel, the FSM depicts some wonky special service tool, presumably a custom puller

 

So I ordered the parts for the front diff flange dust cover and seal thinking nothing of it, and I've now learned about pinion preload...

The FSM has a large section of the disassembly and reassembly of the diff including setting preload, but I'm not sure I want to get into that. Given I haven't disassembled the drive pinion or flange assembly at all yet, if I were to just put the ring gear cluster back into the clamshell and button it up, do I need to worry about any calibrations? There's another section regarding how the ring gears runs with the drive gear using lead paint to see the wear patterns, so I guess that's what I'm mainly worried about. If anyone is perusing this and has thoughts let me know!

 

If it were me I'd probably just reassemble it, assume it's all good, and send it.

Chances are it's never been disassembled and the preload and runout are fine. If they're not, you could have to replace the diff (and they're pretty cheap and readily available).

I'd bet the cost of tools you'd need to check preload/runout would exceed the couple hundred bucks to replace a diff. Same likely applies for the price of a diff shop to check those settings too

 

That's what I'm thinking too, as long as I didn't mess with any of the gearing or bearings/spacers I'm hoping it'll just be fine. I wouldn't mind doing that sort of project sometime just to learn about it, but since I'm putting a lot of effort into restoring this particular diff I'll do my best not to screw it up lol. Thanks for the insight!

 

Hell yeah dude! Conversion gang

 

Picked up a massive parts order from the dealership today, I'm on a first name basis with the parts guys now lol. Massive bummer is that I placed the order which was like $350 literally one day before Toyota started a 25% off all parts promo...so that sucks. I still have to buy some big ticket parts so will still take advantage of it though (I had no idea you could still buy the manual hubs brand new from Toyota, so definitely getting a set). This order was mostly hardware and seals. Also finally getting some paint on the parts, finished up the CV axles, front diff brackets, and front driveshaft. Everything looks so good cleaned up with the fresh hardware. I'm getting kind of sick of the restoration phase of this project but I know it'll pay off in the end to have crispy parts when I'm putting it all together.

 

Looking good man. It'll be totally worth doing all this work IMO

 

BTW what are you using to paint these?

 

Love the extra steps you're taking in the parts prep. Will look great when assembled.

 

The black I'm using is just Rustoleum Flat Black, but I've either been using self etching primer or a rust encapsulator first! The driveshaft I was able to sand down to bare metal pretty easily but the CV stuff and the diff had some areas of light pitting so I just got as much of the rust out as I could with evaporust/wire wheel/sanding/die grinding and then coat it with the encapsulator. Seems to be working well, we will see about longevity! Everything is going to have quite some time to cure since I'm not really close to installing yet.

 

Thanks! Yes I think it'll be worth it in the end for sure, and hopefully won't have to touch it for a long time once it's all bolted up.

 

Finished getting the front diff down to bare metal today and got it masked to paint. First coats today were with a rust reformer, will top coat it tomorrow with flat black. While that was drying I also got the new seals on the CV axle and reassembled one of them with a new reboot kit. The side with the star bearing was a pain to get back together, but lots of swearing later it's all sealed up with 100% OEM parts! Before and after pics for comparison of when I picked it up from the junkyard.

 

Also just got my PartSouq delivery, I ended up ordering the three transfer position switches, VSS, front diff rear mount, and a few other things through them. It seems like for big ticket stuff its worth it to use them, even though shipping can stack up quick. I think I saved something like $300 vs. buying through Toyota online, most of the items were roughly half price what they were from Toyota. Shoutout @Area51Runner for the VSS write up, I just mocked up the sensor and everything appears to be good to go. Switch fits in the transfer case perfectly and the 30 tooth plastic worm gear matches up inside the t-case and turns with the gear!

 

Really looking good!

 

Makes me want to start another tacoma project. Good work man