Darth Haul - Dark Yota build

Motor is out! Wasn’t pretty, but it’s done.
Damaged the AC condenser and Frame crossmember in the process...
but it’s done. Truck is back in the garage.
Time to move on the next step.
Got both engines side by side, will check which parts are missing or should be swapped from old to new.
Have to order some new exhaust manifold studs and bolts.
New clutch and pressure plate. Clutch master cylinder, and some other knick knacks.

 

Tried to take the exhaust manifold off this weekend, but theres a couple bolts that are reeally stuck.. so, I took off what I could off the old motor, and started taking some stuff off the new one too to get ready to pick er up and drop er in.
Removed the air cleaner assembly & upper intake manifold. Removed the wiring harness. And cleaned the block a little bit where the exhaust manifold bolts to the new engine.

Pulled the carpet up in rhe whole cab. Was really rusty in the drivers side! Thats why I did it.

Scraped up the underlayment, rust, hit it w steel wool. Patched a hole with a tin can lid &some liquid nails, and then painted with some black rustoleum paint.

Will need to replace the underlayment with something. Sound dampening, insulation stuff.

Ready to buy a new clitch kit next. Rock auto has a deal on an AMS clutch, + Flywheel +slave & master cylinders for $375 after rebate, so im gonna do that.
The flywheel on the new engine doesnt match mine. Its off an automatic (?) '07 FJ cruiser, & mine is a 2" thick dual fly? And it is fried too.
Also hit the bell housing inspection cover with Steel wool. The gasket was shot and it was bemt too, letting all kinds of crap in to the clutch. Ill have to replace with some new foam or rubber.

If my neighbor doesnt help me get the bolts out on this manifold I just might buy the headers after all!
Taking a week off next week to travel to CA. Woll get back after it when I return.
Cheers.

 

Back from my trip to CA recording music, and working on hydrogen station development.
Ordered my clutch kit last week, and it all arrived today! Had to get back out to the garage even though it was 20 degrees outside (it was sunny at least).

Was able to get the old fly wheel bolts off the old motor. Then, cleaned the crank mounting surface with brake cleaner.

Realized I need loctite to put the new bolts in when I mount the new flywheel. Will get some tomorrow.

Meanwhile, used my angle grinder and got the last 3 stubborn studs & nuts off the old block. So I was able to get the old exhaust manifolds off! Now I can reuse them and save a lil dough.
(At least until I’m able to afford headers..)

 

Dude this is amazing- you are putting in WORK. Please keep us updated man I love seeing this thing being brought back to life. Looks like you will have a really well built truck when all is done. Can't believe how fucked the old engine was, how many miles was on it? It takes a lot to do that to a Tacoma.

 

Thank you very much.
Yeah it’s been a pretty serious endeavor! Haha.
Yeah I hope I will have nice capable 4x4 vehicle for less than what it’s worth when I’m thru. I have been through just about every inch of the thing it feels like!

Truck had 110k mi on it when I got it. I agree. No idea how the PO fucked it up as bad as it is except serious neglect and abuse. Figure the head gasket blew and he drove it like that? Then threw a rod.

This weekend I’ll be putting the flywheel and new clutch on, and then I can put my new motor in the truck.
Feels good to be reassembling now instead of ripping stuff apart Turning a corner here I hope.
Thanks for the encouragement!

 

Awesome man I will be checking back for sure. Excited to see this thing brought back together. Can't believe it was in that kind of shape with such low mileage. Will definitely be a fun 4x4 with the manual transmission.

 

Going skiing this weekend. but gonna try and get out in the garage too tonight and/or Sunday. plan for next couple days is:

• mount new flywheel. threadlocker, torque wrench.
• Buy Exhaust manifold stud bolts (done); install studs into block
• Buy New hydraulic line (between clutch slave cylinder and upper clutch line). install line onto tranny
• buy new grommet for floor (done)
• buy clutch alignment tool (done. arriving this wknd hopefully)
• Mount clutch pressure plate
• Buy new AC Condenser (done)
• Install new engine... we'll see if I get this far this weekend.

 

Flywheel on, clutch and pressure plate are now mounted!
Ready to drop the new motor into the truck tomorrow

 

Got the engine in!!
Stoked.
Put the flywheel on Friday night. Clutch plate on Saturday. And now engine in Sunday. Had to plow some snow first, but chained the engine up and picked the engine up w the tractor and it was nicely balanced. Neighbor came over to help.
Fit right on the mount bolts. Done in 5 min.
Pushed it back in the garage. Started putting parts back on. Got the AC compressor, power steering pump, starter and alternator on. Had to fix the starter after I broke the housing getting it off the old motor. I used some JB weld and some camo duct tape- so you know it’s good!

Wiring harness mostly on. Tranny under the truck ready to put in.
Can’t believe the truck has a power plant again! Turning a corner here.
See if I can get her running this week.

 

Tonight I removed the accumulator. Thanks for the tips Tacoworld!
Also had to put a new gasket on the clutch bell housing cover.
Built a trans mount for my floor jack out of plywood and 2x4s.
Got it under the trans under the truck.
Ready to lift er up and slap her into place! Maybe tomorrow? This weekend for sure

 

Alright got the transmission back in! My makeshift trans-mount worked pretty good. It was a little hairy, but I didn't break anything.

Spent a long time on this truck last night. installed the new A/C Condenser (shiny), re-installed the Radiator,
put the front driveshaft back on. still need to do the rear.
put the upper intake manifold and throttle body back on with new gaskets.
mounted the exhaust manifolds and new gaskets.
put 5 qts of oil in. Need to top it off and swap the oil filter for a new one later today.
added 1 gal of coolant. got some more today.

still need to:

• add fluid to the transfer case.
• change / add fluid to the transmission
• change / add brake fluid to brake / clutch system.
• connect slave cylinder line to master (new union), bleed clutch hydraulic line.
• re-install shifter, drivers seat.
• put the battery in...

start er up! see how she runs. stoked.
hope I can fire er up tonight.

 

Nice. Subbed.

 

awesome thanks.

 

Alright got the transmission fluid all drained, and refilled s fresh fluid.
Bled the clutch hydraulics. Had to redo the coupling I used to remove the accumulator.
Got the thing all ready to start. Tried to start and she just made clicking sound...
I’m thinking it’s the starter. It’s probably shot after I broke the housing.
Gonna pick up a new one tomorrow am. Napa auto special. Guess we’ll see if that does it.
Thought about push starting er up...
But since there’s no fuel in the lines anymore, it may not start. And it would be bad to screw something up now after all that work.
I also somehow misplaced the radiator cap when filling it up?!

Tomorrow. Hopefully I’ll get to start er up.

 

She Lives!!
Had to replace the starter yesterday. But got her started up. I can hear the throw out bearing spinning though. It is touching the pressure plate fingers.
Got to adjust that today.
But otherwise the brakes seem to work okay, and the truck handles nicely!
There’s a little clicking noise when shifting into 3rd gear. Not sure what that’s about. But, I’ll drive it around some more today and see if it keeps going.

 

Short video of it running here

 

The 4x4 light went off after I plugged the wiring harness into the front diff! haha. oops.
check engine light still on. Going to be taking it to the stealership Thursday to have them go through it.
Snow in the forecast tomorrow! will get to test out the four wheel drive Tues / Wed.

 

Drove it home in the snow yesterday & it handles great! 4.5” of fresh snow, no problem. Needs some weight in the back tho.
Stopped and got some new wipers too. Update today: Bitch is street legal now!!
Passed inspection yesterday, registered today. What’s up?

#JetBlack

 

After reading this thread completely through, made me wish for the good ole days when rebuilding a ford or chevy wasn't very hard. I've done 1 ford engine, and 2 chevy 350 small blocks. Piece of cake compared to this nightmare. You should be extremely proud of yourself for pulling this job off. I'd be walking ten feet tall after completing a task of this magnitude. WAY TO GO!!!!!

 

Thank you very much! I appreciate the kind words. My back definitely hurts, but I am proud of my work.

Update: dealer looked at my clutch and said everything is working as it should be! Throw out bearing is not touching the pressure plate when diesengaged. (Dude said if it was they’re isn’t anything they could have done anyway as it would have b/c of installation error).
Good thing I didn’t screw anything up!
Also, they pulled vacuum on the A/C condenser loop and it held pressure! So, no leaks. Charged it up and it blows cold.

Had em do the driveline service. Greased up the propellers, and changed the fluid on the differentials. I do need to replace Both front CV Axles! Opted not to have them do it so I can save some $$$

I had an old ‘66 Ford Ranchero that I used to wrench on and a VW bug I swapped the engine on when I was in high school. That swap was really easy. Hardest part was getting the engine in there. Also had an ‘70 F250 with a 390 cu in V8. That thing has so much room in the engine compartment you could leave your tools in there and drive around town! Haha.

But yeah, this was a bear. No doubt. It was very complicated!

Happy that the truck is back on the road and hopefully will be good truck for my family and for years to come.
Thank you again.