BigMike’s Big Journey: New 2016 Tacoma

nagorb · May 13, 2018

BigMike[OP] said: ↑

I posted a FAQ to another thread and I'd like to include it here in case it can help answer some questions

How can a truck go so slow without dragging its brakes, and how can it possibly climb a rock taller than itself without any throttle or even a driver?
It has a Marlin Crawler TacoBox.

What is a Marlin Crawler TacoBox?
A Marlin Crawler TacoBox is our dual case setup for automatic or manual transmission 2.7-liter, 3.4-liter, 3.5-liter, 4.0-liter, and 4.7-liter Toyota 4WD drivetrains for T100, Tacoma, 4Runner, Tundra, FJ Cruiser, Sequoia, and GX470.

Side note: The name TacoBox is derived from "Tacoma" plus "Crawl Box" (our nickname for our classic 1979-1995 dual case setup). Its name was inspired by the Tacoma because it was first used in a Tacoma, July of 2000, when Marlin Crawler became the first to Dual Case a Tacoma. It fits many non-Tacoma drivetrains (listed above) and we've been installing Dual Case setups into 1995 and newer Toyota trucks ever since!

Required modifications
The TacoBox measures approx. 8.5" in length and is inserted between your existing transmission and transfer case. Because the transfer case is moved reward 8.5-inches, the front drive line is lengthened 8.5" and rear shortened 8.5". On applications with a two piece rear drive shaft, only the front piece of the rear two-piece drive shaft is shortened and the factory carrier bearing remains in it's original position. To operate the TacoBox, an additional shift lever is installed into the interior. This is the only aspect which is not "bolt-in" as some custom work is required along with a new boot from your local upholstery shop. Shifters can be positioned within about a half foot radius to the TacoBox to decide to sacrifice a cup holder, or coin tray slot, or plastic bezel, and so on. Here is a gallery of examples on various vehicles https://www.marlincrawler.com/tech/transfercase/marlin-crawler-interior-shifter-picture-archive

What about crossmember modifications?
Cross-member modification is only required for trucks with a solid / live front axle. The majority of TacoBox-compatible trucks do not need to worry about this. Even on 100% stock trucks, the TacoBox may be installed without any crossmember mods and while using the original factory crossmember without any issues. (In fact this is how I ran my first TacoBox setup and ran Moab once, Rubicon twice.) The TacoBox does, however, have a provision for an extra crossmember mount which the installer may chose to utilize which will extend the life of both the original crossmember mount and both engine mounts. It will also provide more drivetrain rigidity for improved power transfer both under drive and coast conditions.

Does it alter the way the vehicle operates, computer interference, gas mileage, daily driveable?
When the TacoBox is not needed, it is shifted into HIGH which is a 1:1 ratio. Torque enters and exits at the same rate. Other than an extra 45 pounds, the truck has no clue the TacoBox exists. You can daily drive the truck both city and highway like normal. Fuel mileage is unaffected (<1%). You can shift your stock t/case into LOW and be just like any other truck on the trail, having the same final drive ratio as factory. Toyota's "Crawl Control" gimmick will function like normal. ABS functions like normal. Brakes function like normal. Throttle response functions like normal. And so on.

But, if you encounter an obstacle on the trail that requires more control, more traction, more finesse, and more safety, you simply shift the TacoBox into LOW and your off-road capability become a reality at the flip of a lever.

Does anyone need to be as slow as my truck in the above video?
No, this amount of reduction is too slow and is not practical for everyday trail use. We believe the "Ultimate" Rock Crawling ratio for automatics is around 180:1 (stock is 36:1) and for manuals is around 250:1 (stock is 44:1). These ratios are achievable with the Dual Ultimate TacoBox (equipped with our 4.70:1 gear set) which is also known as a "TacoBox Supreme". Therefore, my Tacoma in 1st gear is more than twice as slow as anyone would ever need to be for even the most demanding off-road scenarios.

If it's unnecessary, then why do I have Triples?
Like Marlin, I installed a third reduction unit for a number of good reasons applicable to me:
1) I can demonstrate all available Marlin Crawler product ratios including the factory gear-drive ratio used in right-hand front axle setups,
2) I can fully demonstrate the raw power of what it means to truly "Rock Crawl" as originally intended by Marlin when he invented the hobby/sport of Rock Crawling 24 years ago (see our History page for details: https://www.marlincrawler.com/about), and
3) Beings I'm Marlin's offspring, it's the law of the universe that I run triples in all my trucks

What is the speed of BigMike's Tacoma as shown idling in 1st gear?
Approximately 0.11 MPH or 9.1 HPM (That's Hours per Mile).

Cost?
To more than double the off road capability of your Tacoma, taking your stock 36:1 automatic Tacoma to a 82:1 ratio (or 100:1 for a stock 3rd gen manual Taco or similar), it is around $1,800 for our standard 2.28:1 TacoBox Dual Case Setup depending on application.
To more than quadruple the off road capability of your Tacoma, taking your stock 36:1 automatic Tacoma to a 170:1 ratio (or 208:1 for a stock 3rd gen manual Taco or similar), it is around $2,200 for our 4.70:1 TacoBox Supreme / Ultimate Dual Case Setup depending on application.
Additional costs are having your local drive line shop modify and re-balance your drivelines (approx $200-$250), a custom shifter boot made (optional), soder to lengthen t/case shift solenoid wires (if applicable), and some gear oil. Done.

Which route do most customers go with?
Ninety-nine percent of our TacoBox customers choose the TacoBox Supreme. The 2.28:1 TacoBox is very rarely requested and we don't even list it on our website. The reasoning is as follows: The standard TacoBox ratio of 2.28:1 is, practically speaking, nearly identical to your 1995+ truck's stock t/case gearing of 2.57:1. Putting either case into low range would yield no net difference in use on the trail. Therefore, in order to "Crawl", you'd have to have both cases shifted into low range at all times, and that would be it, your maximum reduction of 5.86:1 (compound low at 2.28 * 2.57).

On the other hand, with the 4.70:1 ratio of our TacoBox Supreme, you have three very distinct t/case ratios: 2.57:1 (TacoBox in HIGH + T/Case in LOW), 4.70:1 (TacoBox in LOW + T/Case in HIGH), and 12.08:1 (TacoBox in LOW + T/Case in LOW, aka the "Ultimate"). Moreover, shifting only just the TacoBox into low range, you're nearly already twice as slow as stock with only the use of one shift lever. Then when you approach an obstacle that demands maximum traction and control, you still have the combination of engaging stock t/case low range at any time for a super-low compound t/case ratio. For a price difference of only ~$400, it is easy to see why if you're going to go Duals then why not go for the Ultimate setup.

How did I come up with more than 6,000 lb-ft of torque from an idle?
While I have not worked out hand calculations yet, I am certain the amount of torque (moment of inertia) present in a 45-50 lb flywheel/clutch assembly rotating at 600 RPM (my idle speed) is more than 10 lb-ft of force. I bet it's closer to 25, especially when you include the ECU metering air and fuel to maintain idle speed under a load. If we consider the conservative 10 lb-ft figure, then not including small percent losses, we have 10 lb-ft * 580 = 5,800 RPM......at an idle. The upper range (a range I feels is more accurate but would rather not state until proven on a dyno [something I am working on]), would be 25 lb-ft * 580 = 14,500 lb-ft torque. Fifteen-thousand pounds of torque...quietly...idling. Whatever it is I will bet my pink slip that it's higher than 6,000 lb-ft of torque at an idle without any throttle input.

So even with only an estimation of 10 lb-ft of engine torque, a value a child could easily exceed while arm wrestling, and we've already got nearly six-thousand pounds of force. This is the raw power of the Marlin Crawler and given this immense degree of control is why we do not experience bouncing, breaking, trail damage, roll overs, or risk to our selves, or our cargo, or our vehicle when the Marlin Crawler is engaged.

With all this torque why do parts not break?
It is true that if you were to cement all four tires to the ground, engage double-low range, and put the pedal to the metal with your eyes closed then something will definitely blow up.

But precisely because we have so much added control from the TacoBox, we have nearly 5 X more reaction time to listen to the truck, feel the engine slowly load up, hear the suspension begin to settle, and feel the vibrations in the seat from the slow rate change of RPM to finally think to yourself...

...and then you shift into Park, turn the truck off, get out, and then realize that your rear tire was trying to climb out from an undercut rock, something so impossible that had you not had a TacoBox, you surely would have broken an axle the second time you tried whacking the skinny pedal.

It is this extreme degree of control that in fact prevents us from breaking parts. Considering how much time you have to avoid destruction, you literally have to desire to break an axle when the Marlin Crawler is engaged. In fact my 1981 has been Triple Case'd (511:1) since 2004 and I have never broken an axle even with bias-ply 37" Pitbull ROCKER tires because I have the ability to listen to the truck's feedback and safely come to a stop before any failure occurs.

It's the same when discussing potential roll overs. Because we can now go so slow, you can feel the lean of the truck and have time to mentally asses each situation and simply chose to stop the vehicle before any permanent damage is done. Compared to revving the engine to generate necessary torque to turn the tires resulting in as we all know a lot of bouncing, once you start bouncing, gravity and suspension rebound take over and either cause parts to break or your truck to uncontrollably bounce off course. Don't do this. Get a TacoBox to protect and preserve your ride no matter what the trail throws your way!
Click to expand...

Lord Humongous said: ↑

Is it a cable shifter? Could it be positioned somewhere more discrete if wanted?

Amazing truck by the way! Love that your running 40s with IFS!
Click to expand...

Lord Humongous · May 13, 2018

So is it a cable shifter?
Thanks for trying though.

nagorb · May 13, 2018

Well the answer to your question is right there.

svdude · May 13, 2018

It's not a cable shifter, he just made a new panel to cover a part of the tunnel area for a new shifter assembly. I don't think I have seen and cable shifters for Toyota t-cases. If you have please send me a link.

Lord Humongous · May 13, 2018

svdude said: ↑

It's not a cable shifter, he just made a new panel to cover a part of the tunnel area for a new shifter assembly. I don't think I have seen and cable shifters for Toyota t-cases. If you have please send me a link.
Click to expand...

Ok makes sense. I was curious how it had different mounting locations. Sounds like the actual shifter shape is modified to accommodate shifter location in the 6" radius. The crawler box is an awesome upgrade, just thinking about how clean the turd gen interior looks. Stealth lever option would be nice!

svdude · May 13, 2018

Yea, I would love to add a crawl box to my taco... Hint hint Mike, when is your website going to have parts for our third gens to accommodate this crawl box you so openly brag about?

Also, do you plan on having a 4.7 crawl gear that will work in either out transfer cases or a FJ cruiser case? I would like to have a FJ cruiser manual shift case in my truck. Waiting for the electronic shift is annoying at best.

BigMike · May 14, 2018

Sorry I have not responded yet to questions. I'm working on getting caught up with work while gone to Texas....and now it's quite very much possible that I am in a small hotel on another road trip to Moab

I do however have this to share: My first MarRack Stress-test Video

It's a known fact that stock tie rods fail with as little as 33" tires, and the stock steering rack fails with as little as 35" tires. Testing this with both 40" tires and the incredible torque from a 580:1 gear ratio was a great way to warm up the MarRack for some wheel'n.

So, what do you guys think? We are planning additional stress test videos in June for some more demanding situations, such as more throttle and wheel speed...

https://www.youtube.com/watch?v=7v6PGjjO3_c

tetten · May 14, 2018

BigMike[OP] said: ↑

Sorry I have not responded yet to questions. I'm working on getting caught up with work while gone to Texas....and now it's quite very much possible that I am in a small hotel on another road trip to Moab

I do however have this to share: My first MarRack Stress-test Video

It's a known fact that stock tie rods fail with as little as 33" tires, and the stock steering rack fails with as little as 35" tires. Testing this with both 40" tires and the incredible torque from a 580:1 gear ratio was a great way to warm up the MarRack for some wheel'n.

So, what do you guys think? We are planning additional stress test videos in June for some more demanding situations...

https://www.youtube.com/watch?v=7v6PGjjO3_c
Click to expand...

I think: spend less time answering questions, spend more time on R&D.... after rack goes into production, THEN answer questions

I may be biased by the desire for steering that doesn't suck while aired down on 35s though

Spvrtan · May 15, 2018

Any plans on working on a box for the 2007+ Tundra!?

I'm supercharged on 4.88s but would love to have a 2nd transfer case for crawling..

https://www.instagram.com/p/BicQ00rAOq2/?taken-by=spvrtan

snowsk8air2 · May 15, 2018

BigMike[OP] said: ↑

Sorry I have not responded yet to questions. I'm working on getting caught up with work while gone to Texas....and now it's quite very much possible that I am in a small hotel on another road trip to Moab

I do however have this to share: My first MarRack Stress-test Video

It's a known fact that stock tie rods fail with as little as 33" tires, and the stock steering rack fails with as little as 35" tires. Testing this with both 40" tires and the incredible torque from a 580:1 gear ratio was a great way to warm up the MarRack for some wheel'n.

So, what do you guys think? We are planning additional stress test videos in June for some more demanding situations, such as more throttle and wheel speed...

https://www.youtube.com/watch?v=7v6PGjjO3_c
Click to expand...

Heading to Moab you say, I'll be there next week and could use a marrack to save my alignment.

Also you going to be at the overland expo in flagstaff this weekend? I'm debating going or not, but might reconsider to see this thing and talk a bit

Lord Humongous · May 15, 2018

snowsk8air2 said: ↑

Also you going to be at the overland expo in flagstaff this weekend? I'm debating going or not, but might reconsider to see this thing and talk a bit
Click to expand...

Second that! I'll be there and love to see it in person!

mcharfauros · May 22, 2018

BigMike[OP] said: ↑

January 14, 2018: First day back at home on 40s and prototype Marlin Crawler front bumper

That first day back home I couldn't even run to Starbucks without a guy stopping me in the parking lot asking questions about the truck. I showed him the TacoBox Crawler and the work I've done to make this happen, gave him my business card. While chatting I noticed bros wearing flatbills in their lifted American-brand full-size pavement pounders gazing over at the Taco while slowly driving by.

Heck yeah!! Get'n respect for the new 3rd gen like never before!! But there is A TON OF WORK still remaining to get this truck trail worthy again. Currently it's just eye candy. The next Rock Crawling event is in March. I'll work very hard to get it ready by then!

Click to expand...

Any chance this bumper will go into production?

no mods · May 29, 2018

Few east coast rigs are eager to get our hands in a rack
. Keep up the good work.. if u need some extra test mules we are pretty hard on parts.

BigMike · May 29, 2018

Hellllllllllllllllllllllllllllllo build thread!

Sorry, only here for a quick update. I've been busy really, really enjoying this truck. Started May at 17,329 miles, now at 23,355! Heading out for more this weekend!

After climbing the following in Utah, I thought to myself for the first time... wow... this Tacoma has, for the first time, surpassed my 1981 Hilux Rock Crawler in some ways. Rear tires in sand with an undercut ledge. Never thought it would climb it. My camera man had to turn into a spotter so sorry no video footage. I'll say this: The MarRack got a serious workout with some skinny pedal and essentially FWD 40" tire hop

The engine was flooded with oil and shaking at idle but still had good power once revved up. Took more than half an hour for smoke to clear out the exhaust. Good news for my fellow 2GR-FKS friends: I *think* I've found a fix for the excessive high-angle smoking Will definitely be posting about it!

Took the steepest line possible right in the center

Got a ton of updates to post and falling behind week by week and love'n the hell out of this truck

Here I am watching a customer experience low gearing of the TacoBox for himself. Afterwards I realized this was the first time I've had someone drive my truck off-road. Of course there is zero fear with the Marlin Crawler engaged; Go nuts, floor it lol You won't get very far hahah

I've got many more Moab + southern Utah wheeling pics to post to my Trip Report Thread (once I get that thread caught up)

BigMike · Dec 5, 2018

Recently on Facebook a few pics from the Texas short-course timed competition have surfaced. Thank you to the Jamboree for sharing these!

There were a few people filming my run but so far I've only found this one 39-second clip from where I got out of the truck for a few laughs right in the middle of the race. (If anyone knows of a full-length video of my run then please let me know!! Thank you!!) I stood on the front-right tire while it was still in gear and moving

https://www.youtube.com/watch?v=C-TF1tx_VwY

Update Dec 5, 2018: I forgot to add another video here!

http://www.youtube.com/watch?v=n6sexmm92m4

Rich from the Toyota Truck & Trails Podcast filmed this casual TacoBox demo earlier this month and just recently shared it too

https://www.youtube.com/watch?v=7gJxFOEIoh8

We've put together a small (but growing) TacoBox YT Playlist here. Currently has 8 videos:

https://www.youtube.com/playlist?list=PLlZHPeT0qMldxTtB41htd3A-0zBP8dAhc

Might have some time later this week to post up some updates! Hope everyone has been having a good spring season!

Catch ya on the trail!!

BigMike

snowsk8air2 · May 29, 2018

no mods said: ↑

Few east coast rigs are eager to get our hands in a rack
. Keep up the good work.. if u need some extra test mules we are pretty hard on parts.
Click to expand...

And one test mule in AZ willing to put the marrack through both fast and slow stuff.

I must have just missed you in Moab @BigMike. I was there last Wednesday thru Friday

Had to show my Jeeping buddies on 37's how tacos do it on 35's

BigMike · Jun 10, 2018

https://youtu.be/WrRBbh6-eGU

svdude · Jun 10, 2018

That's very impressive!! Now sell them to us.

Edit: i see they're on your website now. Nice! I'm loving it!

RedBeard1 · Jun 10, 2018

@BigMike

When are y’all going to give us some Marlin heavy duty clutch goodness?

tacoma16 · Jun 15, 2018

in for all the goodness and steering upgrade!

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nagorb Should be a dang perma mod

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nagorb Should be a dang perma mod

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Spvrtan "Your assembly required."

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