Matthew's Jade Green 4x4 Conversion. (and other upgrades)

Not that this thread will add anything to what is already out there but here is my 4x4 build of which i am open to any and all input on doing this conversion. I for sure will have questions and appreciate in advance the guidance.

I will already give a huge shout out to Tour991 for taking time to educate me on this project.

I am starting with a 2004 Jade Green Double Cab. 3.4L V6 with about 175K miles on it. I have owned it for about 8 years. Love it. It is my daily driver so this conversion will be done is steps.


Why am i doing this? Our Boy Scout troop does outings from time to time where the trails require 4WD. I was going to sell my DC and buy one with 4WD but was shocked at the price for a 20 year old truck. So hence here we go with another conversion thread.

My plan. To do this in phases to maintain a drivable truck. Weekend warrior type stuff where i will prep things along the way and install in batches. The goal here is totally manual so that my truck's electronics does not know otherwise that it is 4x4.

- Step 1. Rebuild Manual locking hubs with spindles on donor ABS brackets and install.
- Step 2. Rebuild 4.10 Differential with manual tube and new axles seals and isntall
- Step 3. Rebuild manual axles replacing boots but do not install yet.
- Step 4. Rebuild J shift manual transfer case with new seals.
- Step 5. Rebuild A340F transmission and install with transfer case.
- Step 6. Install drive shaft & axles and bring it all online.

At the same time i will probably put some sort of lift on the front end to level out the 5 leaf springs i have in the rear plus the additional weight added to the front. This will be done simply with levelers.


My time frame. i 6 months. I started with research about 1 month ago and already have some parts sourced. The only mechanical aspect i am worried about other then brute strength to install things is the transmission.

The parts i already have source:

Manual Locking hubs, spindles, axles and Manual front Diff tube.


4.10 Front Diff. Has ADD but that will be removed.


ADD front spindles that will be my ABS donors. I plan to build up on these spindles to minimize down time on my truck. Also my 2WD spindles have brand new bearings so leaving them intact will allow me to sell them off when done.


Other parts i have coming are:
- Front wheel bearings and seals
- Front bearing clips
- Manual hub 4 pin driver tool
- CV axle boot kit

Things i know i am missing or that need research before i make a move.
- Differential shaft seals
- A transmission plan. (More on that later)
- J shift transfer case. (More on that later)
- Manual locking hub rebuild parts
- Grey 4WD console
- 4WD indicator light
- Speed sensor.

Transfer case. Alot of info out there but then again not alot. I think i am looking for any transfer case from a Gen 1 Tacoma or Gen 3 4Runner V6 that does not have any type of button on the shifter. I am not totally sure this is accurate though and therefor have been searching for definitive information. I am also not sure if mileage on these is important or if they are simply rock solid.

Transmission.
My musing right now is:
- Do i pay someone to rebuild my A340E with a new output shaft?
- Do i learn myself how to rebuild my A340E with a new output shaft?
- Do i buy a used A340F with electronic kick down?
- (edit) Looks like the Jeep AW4 is the same transmission as the A340.

I have been reviewing all options. I need a 03/04 Tacoma transmission if i buy one because of the electronic kick down. Do i really though want to buy someone else's problem? I have been looking at A340 tear downs and it does not seem that hard. A rebuild kit is $300 and the other parts should be a few hundred and i end up with a rebuilt tranny. The down side here is i have never done this and while i am super mechanical i have no mentor to guide me.

I also know that if i go the rebuild route i need to source at least two parts. The rear nose cone transmission mount plus of course the output shaft.

This will be left to the end so i have some time.

So lets get going.
That is what i want to do and why. If you got this far then maybe you can lend me some advice and i hope as i go i can add some things to this thread that is new or unique. I will also link below the threads that i am referencing for others to see.

What is this going to cost me?
(This info has been added starting in Jan 2019 since i am well underway.)

My goal was to do this for under $1500. More than half way into this i realize that if i am going to do this then there are certain parts that i want to replace since i am in there. (Ball joints, seals, axle boots, etc.) To that end i will be over my estimate but...

Below is the status as of Jan 2, 2019. Items in yellow are estimates or not yet purchased.

 

Left blank for links to other threads i reference.

Transmission Info
Transmission swap with new Factory A340E to A340F conversion A340E tear down video. https://www.youtube.com/watch?v=zupJVX5XtAs
Transfer Case removal video. https://www.youtube.com/watch?v=oZDSjlxl2Q4
Transmission removal video. https://www.youtube.com/watch?v=O4GA3UhPC5Y
4Runner differences. https://www.tacomaworld.com/threads/differences-between-4runner-and-tacoma-transmissions.270376/
Transmission Swap. https://www.tacomaworld.com/threads/transmission-swap-write-up-s.384303/
Rebuild Kit. https://www.oregonperformancetransmission.com/mm5/merchant.mvc?Screen=PROD&Product_Code=OPT-A340-RB
A340F Tear down. https://www.youtube.com/watch?v=vatOfJozFx0&list=PLTeHYfJ3mKoVnqwZ-b0tDindQ5GIvXadz
A340E/F rebuild kit. https://www.oregonperformancetransmission.com/mm5/merchant.mvc?Screen=PROD&Product_Code=OPT-A340-RB
IPT Transmission A340 Rebuild #1. https://www.youtube.com/watch?v=k8EOwT__ZUY
IPT Transmission A340 Rebuild #2. https://www.youtube.com/watch?v=APNPMA5RMQM
IPT Transmission A340 Rebuild #3. https://www.youtube.com/watch?v=OG0S2j85uEw
IPT Transmission A340 Rebuild #4. https://www.youtube.com/watch?v=7eHazSn3NNs
IPT Transmission A340 Rebuild #5. https://www.youtube.com/watch?v=jq7VRfOaMAU
IPT Transmission A340 Rebuild #6. https://www.youtube.com/watch?v=xEPhFyYX2zg
IPT Transmission A340 Rebuild #7. https://www.youtube.com/watch?v=xN3EeaZ_VXc
gearcruncher thread. https://www.tacomaworld.com/threads...sions-write-up-your-4-speed-automatic.325531/
A340E to A340F DIY conversion. A3-40LE = A340F Outside tranny part ID thread. https://www.tacomaworld.com/threads...rt-idientification-help.588700/#post-19669146

Transmission Pan info.
https://www.tacomaworld.com/threads/a340f-oil-pan-swap.581044/

Transfer Case Info
Transfer Case ID. Transfer Case ID. https://www.tacomaworld.com/threads/what-year-and-type-of-transfer-case-do-you-have.145974/
Transfer case info. https://www.tacomaworld.com/threads/transfer-case-transfer-cases-in-first-and-2nd-gen-trucks.345652/
Transfer Case Rebuild info. https://www.tacomaworld.com/threads/j-shift-t-case-rebuild.406753/
Speed sensor. https://www.tacomaworld.com/threads/speed-sensor-not-working.349490/
conversion info. https://www.tacomaworld.com/threads/a340f-trans-transfer-case-questions.279292/
J shift vs. ADD info. https://www.tacomaworld.com/threads/transfer-cases.584205/

CV/Axle Info
CV axle rebuild. https://www.tacomaworld.com/threads/cv-axel-rebuild.229864/

Spindle/Hub/Bearing Info
Front bearing replacement video. https://youtu.be/dDivFqFQCus
Front Bearing rebuild. https://www.tacomaworld.com/threads/front-wheel-bearings-shot-try-diy-or-take-it-in.569663/
Front Bearing rebuild. https://www.tacomaworld.com/threads...prerunner-2-wheel-drive.534299/#post-17169746

Manual Locking Hub Info
Manual Locking hub video. https://www.youtube.com/watch?v=TZ2sOfVrnhU
https://www.tacomaworld.com/threads...or-the-1st-gen-tacoma-3rd-gen-4runner.460180/
https://www.tacomaworld.com/threads/manual-hub-conversion.487970/
https://www.tacomaworld.com/threads...or-the-1st-gen-tacoma-3rd-gen-4runner.460180/

Differential Info
http://home.4x4wire.com/erik/diffs/
Front Diff removal and install video. https://www.youtube.com/watch?v=w_gPiDvh9v4

Drive Shaft Info.
Local shop that will chop my axle for $150. http://www.drivelinesinc.com/contactdrivelines/

4WD dash indicator
https://www.tacomaworld.com/threads...a-3rd-gen-4runner.460180/page-7#post-20259662

Other 4x4 Build Info
https://www.tacomaworld.com/threads/frenchtacos-2003-4wd-conversion.442734/#post-12884808
https://www.tacomaworld.com/threads...-truck-04-dc-build-4x4-conversion-wip.540331/
https://www.tacomaworld.com/threads/the-el-taco-diablo-4x4-conversion-and-maybe-some-b-s.562405/
https://www.tacomaworld.com/threads/kens-taco-build-bullet.479750/
https://www.tacomaworld.com/threads/lfaubs-4x4-conversion-overland-build.420105/
https://www.tacomaworld.com/threads/4x4-conversion-thread-idea.516061/
https://www.tacomaworld.com/threads...manual-trans-swap-thread.247243/#post-5942904
https://www.tacomaworld.com/threads/4x4-conversion-thread-idea.516061/
https://www.tacomaworld.com/threads...wd-swapped-extra-xtracab-build-thread.496348/
https://www.tacomaworld.com/threads...or-the-1st-gen-tacoma-3rd-gen-4runner.460180/


Headlight info. (It's my thread after all)
Headlight harness. http://www.headlightservices.com/4runner3.html
H4 upgrade Gen 2. https://www.tacomaworld.com/threads/the-ultimate-headlight-upgrade-h4-not-led-or-hid.398066/
H11 upgrade Gen 2. https://www.tacomaworld.com/threads...rade-h11-not-led-or-hid.435419/#post-12592662
Gen 1 upgrade. https://www.tacomaworld.com/threads/proper-headlight-upgrade.407879/

 

What is the definitive scoop on identifying a j shift transfer cases (TC) for an Automatic Transmission.

- Are AT and MT units the same?
- 4 cyl vs 6 cyl i know the shift arms are different length.
- Button or no button which corresponds to different shift pattern on top of the shifter.
- Is there a way to tell by looking at the casting?
- What to look for in a used TC?

This thread shows the different versions and i am pretty sure the "no button" is the easy key.
(Images borrowed from Brian2sun from above link. Will remove if needed)


So the next logical questions are:
- In what year Tacoma's will you find these?
- Did they come in 4Runners and if they did are they exactly the same?
- Will they always be coupled with manual hub locks or could you have ADD and J shift?

This all comes back to the challenge of identifying the transfer case from low resolution images from sellers who may not really know what they are selling.

Thank you for the guidance.

 

My 2004 is ADD with a J Shift.

 

Thank you Blue92. That helps when looking at for sale ads where they show the axles. I was eliminating the ones with clear ADD hubs. This opens my search up.

 

Today i tackled taking apart my donor spindles. Pulled out my 12 ton press to see if it had enough umph... It did. Cobbled together bits and pieces to make it work.



When i was done i wanted to see what the bearing was made up of so i took the old one apart. I will also use the outer race for a press spacer when i put things back together.


As warned by others i found the large C-clip ends break easy. I had to dig one clip out. I did the "reverse press" thing on the bearing to get the pressure of the clip but one still broke. Broke darn easy too.


Looking over the donor parts i ask myself if these ball joints are still good. How do you tell if they are?

Obviously if they have play but both my uppers are pretty tight feeling. Tight to rotate but the have rusty tapered areas.
Both the lower are much looser and easier to rotate but no real play.
What do you all think? Is it worth the $200 to replace them?

I removed the boot. it is not torn so i can get it back on.

 

What is next?

- Figure out if i can re-use the ball joints.
- Open up the front Differential and confirm the ratio and get it ready for the manual tube.
- Pick up my manual hub parts. (Next weekend)
- Still work towards confirming how to ID the transfer case.
- Still research how to tackle the transmission.

Input is really welcomed.

 

After almost pulling the trigger on a 2002 4Runner trans for a good price i got some fast info from Bartmaster1234 that changed my mind.

Thank you Bartmaster.

The net end results from the conversation is that the 03/04 Tacoma needs an exact match transmission or the output shaft swap.

I was trying to minimize the down time on my truck so trying to avoid the shaft swap. I did find an output shaft for $100 but not sure what i should be paying for that and the other parts needed for the conversion.

1. Output shaft
2. Filter (Easy)
3. Pan magnets (Easy)
4. Tail cone
5. Possibly the transmission support. (This i have not confirmed yet)

Anyways. As always input is welcomed.

 

Good to see another 4wd conversion going on! Sub'd to this thread

 

Yesterday i was able to head out to Apple Valley and pick up my Manual Locking hubs & axles, Manual fifferential tube and front drive shaft. Spend the day taking them apart, cleaning and figuring out what i have. I think i am happy.


Shafts are a bit rusty from where the blue stickers were. I will clean that up and re-paint.

Locking hubs seem fine. Just need to get new gadgets, clean them up and wala. Red or grey is the ultimate question there.



Inner CV's looked good. Both boots were intact. Lots of grease inside that looked clean. No water. Was not able to get the shaft off of the bearing though. Would like to take them completely apart to clean but the "slide hammer" tube technique did not work.


Outer CV's. One was intact and looked great. Clean bearing and no contamination at all. The other had a torn boot and it had been that way for a while. After taking it apart it looked OK but would appreciate some input because what do i know. The three bearings roll fine after a copious amount of cleaning. The outer roller surface has some slight aberrations but they are not pitted and honestly i think it looks fine.





Drive shaft i will tackle later as i am not sure it is the right length. It came from a 98 Tacoma so i hope it works in the 2004 but we will see. (In many months)


Will pull apart the axles today.

 

Today the manual axle hubs were taken apart.


Again the 12 ton press was probably pushed to its limits but both hubs broke free. The bummer part though is that both hubs were damaged in the process. The s spacer I used around the brass nose piece shifted in both cases damaging the top 1/16" on the outside of the hub and taking out at least one full thread. Also one of the brass pieces is a bit wonky now. Tomorrow at i will chuck both up on a lathe and clean up that top thread area. I think i can salvage them but not sure about the brass piece. (Bottom one in image)



OEM spindles are not cheap. I did find a thread talking about the Durago units sold by Rock Auto. Anyone have any advise??

https://www.tacomaworld.com/threads...mbly-w-o-add-found-some.562609/#post-18439184

https://www.rockauto.com/en/catalog...l+v6,1278930,brake+&+wheel+hub,wheel+hub,7632


On a good note I got the wire brush out today and my backing plates and spindle carriers now are clean and painted. I am using Epoxy spray paint. I also made an assumption that a 99 4Runner has the same backing plates as a 2004 Tacoma.

 

Was able to repair both hubs today. Had to remove the top two threads to clean things up so that the nut went on smooth. Still plenty of thread engagement left. I am satisfied.


One of the bronze/brass bushings though i think is wasted. My three options are:

1. Find one loose. A quick search suggests they are not available loose.
2. Make my own. Not a big deal but would rather buy one.
3. Buy the cheap Durago unit and harvest the bronze/brass piece only.

The last one is the easiest but no guarantee it fits. If it is a tad oversized i can always turn it down. If it is a tad undersized i could loctite it in. If it is way oversized then i am OOL. Hmmm.....

Any advise?


In doing more transfer case research it apeers that an ADD unit will have some sort of actuator on the back side which make sense. Thank you JFaub03 for that tid-bit. So, the next questions is there a way to tell an ADD vs J shift other than that actuator? I have found some units for sale that either that ADD actuator removed or the seller did not know what they had.

Here are pictures thanks to Jfaub03. First one shows the ADD actuator. Second does not.




Peter Picked a Peck of Pickled Peppers. How Many Pickled Peppers Did Peter Piper Pick?

 

I fixed the second hub this AM. Was not happy with the threading of the big nut so went back and re-filed the threads. Both now thread nicely.

Last night i confirmed what i already knew in that you cannot buy the bronze bushing for the hub anywhere by itself. That being said my first option is can i repair the damaged one? Upon further review the answer is now way. Not only is it out of round but also no longer flat. Here are the good and bad ones face to face.


Toyota new is not an option and i have my doubts that the aftermarket one will fit so lets make a new one. Should have a few sets done by next week.

 

subbed, mostly want to know what transfer case you will go with. I did the manual hub swap on my truck but still have my stock AAD push button T-case. I want to swap it out to a J shift to make my front end more reliable (less electronics) Im not sure how its all interchangeable with the sensors, still want my 4x4 light to work on the dash and same time avoid getting a check engine light.

Also here is another option for the T-case: (push button J Shift from 1999-2000 limited 4runners)
https://www.ebay.com/itm/TRANSFER-C...=item23a50897a0:g:wcsAAOSwSrxbQ0lA:rk:24:pf:0

 

You're screwed on those Brass rings. No one sells them, I remember countless threads on trying to source the piece.

 

Thanks Shubin for the info. I had the chance to buy a 1999 4Runner limited Transfer cases with the mating tranny but passed it up. Mainly because the tranny is no good to me for anything other than parts.

I must say the transfer case research has been a bit frustrating. Right now i am of the opinion that any Tacoma prior to 1998 is a safe bet. I think that goes for the 4Runner too.

The other bit that is frustrating is i still do not have clear understanding on how the wire for the button for the newer style goes down the shaft to the case. I have not found any good images of that yet to use as another metric for what is what.

Anyways, glad to have someone following.

Matthew

 

Thanks Bartmaster. That is why i am making my own.

Do you know of any specification of what the ID of that bushing is? Or, lets be more basic. What they heck is it there for? The needle bearing just behind it guides the axle stub so i think the bushing just provides some locating for the hub lock mechanism to engage the axle stub. This is theory right now.

 

No idea. If you manufacture those rings, there is definitely a market for them.

 

Yea I kind of gave up on the research of the t-cases. to much to go threw.
I do have a push button t-case sitting in you yard. Its from a 97 4runner. I can send you some pics of the wires if it helps.

 

Subbed for sure. You do incredible work.