Suttonkb Double Cab SAS

Current Pic


Overview:

Vehicle
2002 Tacoma Double Cab Prerunner (converted to 4wd)

Front Suspension / Setup
Trail Gear SAS Kit C
- Bilstein shocks
- Leaf sprung SAS w/ 3" leafs
- Six shooter knucles
- high steer kit
- Longfield 30-Spline
- Aisin Locking hubs
- Chromoly spindles
- ARB Air Locker
- 5.29 Gearing

Rear Suspension / Setup
- Chevy 63 Leafs
- Bilstein 12" Rear shocks
- TG Frame boxing
- TG Shock relocate kit
- LSPV Bypass
- Toyota E-locker
- 5.29 Gearing

Wheels / Tires
- 37" Mastercraft MXT
- 17" Vision soft 8 (4" BS)

Misc
- 12,000 lb Badlands winch w/ synthetic line
- #JeepRecoveryTeam sticker




I just wanted to go through this as it progresses. I've been collecting a lot of parts and doing some miscellaneous things while I saved up for Trail Gear's Kit C. I have finally ordered and received most of the parts needed with the remainder arriving next Monday (5/16). Here's the progress so far.

Traded my 1990 Sas'd 4runner for this 2002 Double Cab Prerunner converted to 4wd that had a completely shot front suspension. The PO told me he used to bounce it up trails to get to the top and on his last trip, he shattered the front ring and pinion. This was essentially the perfect vehicle for me to get since all I wanted to do was SAS it. So the journey begins..

This is essentially how I received the vehicle. A dovetail where no measurements were taken, trimmed front fenders in no specific way, mirror-less doors, worn out suspension, Chevy 63 rear with no shocks, crap front bumper, bent sliders etc.




Step one I replaced the bed with one that had not been hacked up.




Step 2 I replaced the front fenders, removed the crap front bumper, and replaced the plugs and wires. I also rebuilt the rear e locker. I tore it apart, cleaned everything, greased it, and put it back together. It's working flawlessly now. With this I also performed some other minor maintenance.



I have since purchased a kit of Monstaliner in white to paint the whole truck after the SAS is complete.
I then ordered the Trail Gear SAS Kit C w/ ARB air locker and 5.29 gears.
I also bought a new tow pig to pull this thing around with.
The goal is to be able to drive this thing around town and to close events but to tow it to further off events as needed.

Here I was eyeballing what the future setup would look like.



While I was waiting on the SAS kit to arrive (2 months of waiting) I went ahead and had the truck regeared. I pulled the third member and took it to a local shop, Southeast Overland, and had them put 5.29 gears in the third.





In waiting I also realized I needed to redo the rear spring mounts to put the axle in the middle of the wheel well. So I ordered all new Chevy 63 spring mounting hardware from FROR. I'm going to put all this on at the same time that the front swap is happening. I also ordered TGs frame boxing kit and shackle relocate kit for the rear. I went ahead and threw in the LSPV bypass as well since I don't like how much stopping power I'm currently getting with the LSPV.


My 37s arrived and I lined them up to see what the rear would look like.




16 Boxes and 644 lbs later the SAS kit arrives and I can begin to build the axle while I wait on my buddy's shop to slow down in his local fab orders.




So we started building the axle and had to stop after putting in the 3rd to order the other "misc" parts needed to complete the axle build. Had to order hubs, spindle, locking hubs, etc.





So that brings us to today. Today we start cutting the IFS off the truck. The axle parts are set to arrive Monday with the front being welded up and ready to receive the axle on Saturday.

 

That's Matt Young's old truck, from Georgia aint it?

So far so good on the progress

 

FINALLY! A build page! Can't wait to see everything done!

Yes it is! I live right by where he works and used to stare at it every time I passed it lol

 

haha awesome! I've known him through pirate4x4 for probably 6 or more years now and we always talked about getting together to wheel, but his truck was always broke and I sold my old one

Good to see its in good hands now though. Matt talked for years about doing an SAS to it and even bought a couple axles. Can't wait to see it done now. We will all have to plan a meet somewhere up in those parts for a wheeling trip sometime

 

Ha, i wheeled with matt a few times, what a character. Glad you got that hacktastic bed off of there. Good luck washing the fat chick juice out of the seats!!

 

Just finishing my SAS up now. Good luck and should look good! Front axle looks sweet.

 

Got a good bit done in 3 hours. Gonna grind it a little tomorrow to have it smooth for Saturday. Arc gouging made quick work of it.

 

Haha yeah he seemed like a character. I told him I'd show it to him when it was finished.

 

I'm in

 

sub'd

 

Got a nice big pile of junk

 

sub'd! cant wait to see this in person!

 

*Update*
TG boxes were packed by incompetent asians who did not supply any rock ring bolts, any spindle nut kits, etc. So now I've sorted everything out except the spindle nuts and they won't be here until next Thursday (5/26). Yep.

 

Got a lot more done on this thing. Wanted to move the axle as far forward as possible but the steering box wouldnt allow it.


Got the axle under it.




Got it rolling around now. Got a lot of nit picking things to do.
Wire up the arb, tighten stuff down, radiator, fluids, winch plate and wire it up, front driveshaft, steering stops, adjust the shims more, rear frame box, rear shock relocate, LSPV bypass, longer shackles in the rear, install diff breathers, and paint it up with monstaliner

 

Subd for future. Will be doing this to my truck sometime

 

This build is teh gheys!

Jk! Happy birthday again btw!

 

Got the front all squared away so we started on the rear.
I needed to add longer shackles since my stock ones were hitting the frame at ride height and was definitely sitting a little low in the back.
Adding the longer shackles gave us the desired 45* angle and picked the rear up enough. I believe worse case i'll add a 1" block to have the rear where i want it.




While we had the bed off we also boxed the rear frame and started the shock relocate. We will likely finish this up today.




We decided to take a break from the rear and install the new crossmember / skid




Decided to throw the grill back on at the end of the day to see what it would start to look like and i was pleasantly pleased




We decided we're going to keep the bed off in order to make painting it a little easier. Should be pretty sweet once we're done. It's coming together.

 

Looks good. You knocked this thing out quick. The 37s look good on it.

 

thanks! been waiting too long to dilly dally now. haha