wi_taco 2015 TRD OffRoad build "The Gray Ghost"

Hello TacomaWorld! Posting a build thread to document progress on my 2015 Tacoma TRD Off-Road in Silver Sky Metallic acquired July 2020. Because of the color scheme resemblance to the Batman character I'm nicknaming it "The Gray Ghost". Goal for the build is to keep it clean and simple since it's my daily. Feel free to join me on the journey.

Current-ish state of my Taco (04/06/24, ~130k miles):



Wheels, Tires, and Brakes
SCS BR6 17x8.5 -10mm matte black wheels and extended lugs [#44]
General Grabber AT/X 265/70/17 load range C tires [#44]
Tire rotations using Autel TS508 and TechStream [read this][also read this]
4Runner/GX470 03-09 338mm brake upgrade [#87]
Headstrong (Crown) SS extended brake lines +1 front / +4 rear [#87]
Front wheel hub bearings from 05Taco4x4 [#81][#87]
ECGS bushing swap [#87]

Suspension - Current (Set around 2" of lift)
Toyota OEM LCAs replaced June '22 around 111k mi [#121][#122]
Archive Garage Stealth HD U bolt flip & bumps [#96][#115]
Deaver U402 Expedition leaf springs Stage II [#111][#115][#121]
Fox Performance Elite 2.5" front coilovers with DSC [#111][#116]
Fox Performance Elite 2.5" rear reservoir shocks with DSC [#111][#115][#121]
JD Fabrication UCAs [#225]

Armor
4xInnovations bolt-on sliders [#82][#83][#86][#91]
RCI steel skid plates (engine-trans-tcase) [#112][#126] plus UHMW jack pad mod [#196]
RCI aluminum fuel tank skid [#195]
Exhaust re-route for T-case skid [#120 no bueno]
At The Helm 05-15 Standard rear bumper [#149][#165][#221][#224]
Relentless Fabrication Stingray front bumper [#263]

Lighting
Ultimate Headlight upgrade (Pending install)
Spyder Xtune tail lights ALT-ON-TT05-LBLED-RC + Toyota 81555-04150 harness [#64]
Diode Dynamics SS3 Max amber fog lights (Pending install)
Diode Dynamics SSC1 Sport clear as chase lights (Pending install)
Diode Dynamics Stage Series RGBW rock lights (Pending install)
Baja Designs Squadron Sport clear as rear bumper lights (Pending install)

Exterior
AVS stick-on vent shades from previous owner
Front windows tinted 20% to match the rear [#8]
Used Leer 100XL cap - originally red [#14], painted to match Dec-20 [#32], fixed handle [#43]
Toyota PT580-35050-SB rubber bed mat [#32]
Toyota OEM 1D6 color-match grille to delete the chrome [#38]
21" radio antenna A417-TY from TheAntennaSource [#40]
Blacked out front Toyota emblem to delete more chrome [#46]
Tailgate anti-theft device from christian06 [#48]
Rago Fabrication bed channel stiffeners [#52]
Tailgate Bolt Mod for carrying sheet goods [#54]
Spiker Engineering ULTIMATE Lift Hood Strut Kit [#65]
Extang MaxSeal tailgate seal [#106]

Expedition Gear
DCSB Truck Bed Drawer Platform v1 [#65][#99]
Yakima round crossbars + Yakima Sweetroll to haul kayak on cap [#65]
ICECO VL65 dual zone fridge/freezer + slide mounted in cab (rear seat deleted) [#231]
DIY extrusion rack for the camper shell [#235]
23ZERO Kestrel shower awning [#235]
Adventure Tool Company Atlas map case for backup paper maps [#273]

Interior
Husky Weatherbeater floor mats front & back [#9]
BirdDawg Industries "Clearview-Rearview Mirror Riser" [#10]
GQ43VT20T flip key [#19]
Gentex GNTX-453 Homelink kit from Bob's Mirrors [#39]
Blackout interior plastics conversion [#45] and black TRD shift knob [#57][#109]
MESO CUSTOMS v2 dual color LED map lights [#105]
MESO CUSTOMS v2 dual color Ultimate Dome Light [#190]
VLEDS Footwell LED Light Kit [#190]
TUFSKINZ door sill protectors [#107]
Rough Country seat covers [#110]
Hooke Road overhead molle rack [#194]
Cartrimhome LED backlit auto up/down window switches [#207]
Underland Offroad rear molle panel [#243]

Recovery and Safety
4Runner jack modified for Safe Jack extensions [#126]
Maxtrax MKII recovery boards [#144] + Overland Kitted Boomerang Mount + 17mm pins [#235]
ARB Heavy Duty Tire Repair Kit [#188] + Colby emergency repair valves [#208]
Desert Does It Front Multi-Mount Panel + H3R Performance MX250 extinguisher [#189]
Yankum Groove Fairlead + 7/16" soft shackles and offset winch snatch ring [#234][#241][#273]
Bubba Rope 10ft Tree Hugger tree protector [#273]
Factor 55 7/8" x 30ft Extreme Duty kinetic recovery rope [#273]
Factor 55 2" x 30ft Standard Duty tow strap [#273]
ARB 19mm 4.75T bow shackles (ARB2014) as backups [#273]
Adventure Tool Company Recovery Bag to organize/contain most straps/shackles [#273]
ComeUp Seal Slim 9.5rs winch [#239][#263]
My Medic MyFAK first aid kit [#240]
NOCO Boost X GBX45 lithium jump start pack [#272]

Electronics
Blueskysea B4K dashcam with hard-wire kit [#50]
Pioneer DMH-W4660NEX + iDatalink Maestro RR [#46][#50][#70][#227]; List of problems [#95]
X2Power 27F AGM battery upgrade [#101][#104]
HKB MK4 Adjustable voltage booster [#158]
Radioddity GM-30 GMRS HT radio [#114]
12V power system v1.0 [#155]
12V power system v1.1 [#193][#213][#231]
REDARC BCDC1240 DC-DC charger for house LFP battery [#231]
Pelfreybilt mount + Bussman RTMR aux fuse panel [#231]

Maintenance & Mods
Oil changes with Amsoil OE 5w30 and Toyota OE 90915-YZZD3 filters
Differentials and T-case oil changes with Amsoil Severe Gear 75w90
Power steering flush at 118K [#199]
Front diff drain/fill plugs changed to Lexus 14mm style [#71]
Toyota ZKA inspection 7/31/21 [#76] and Woolwax for rust prevention [#20][discount][Read this for a reason why]
Uni Filter UP-107 Mod to mitigate SAI foam failure [#49]
Fumoto F133S oil drain valve [#77]
Extended rear diff breather mod [#90]
Driveshaft U joints, carrier, and re-balance at 127k [#244][#247][#248][#262]

Analytics
Blackstone oil tests: [#55][#56][#72][#135][#192][#208]
MPG calculations: [#36][#92][#176][#264]
Curb weight: [#93][#156][#238]
Wheel alignments: [Aug '20 #94][May '22 #117][Jun '22 #123][Aug '23 #225]

Events and Trips
New Mexico road trip '20: [#18][#23][#24][#25][#26]
Wisconsin Fall '20: [#78]
Wisconsin Fall '21: [#80]
Wisconsin Fall '22: [#152]
TW Mall Crawl and Java '22: [#108]
TW WI Pipeline June '22: [#131][#132]
TW TWAT and camping '23: [#209][#216]
TW TWAT Wyalusing '24: [#280]

Resources That I Found Helpful And Saving For Later
Torque Spec Guide / Parts Manual / Quick Reference / Fox RR rebuild / Driveline angles / Wiring Connectors / A-TRAC/TRAC/AUTO LSD Explained

 

Nice Tacoma, welcome to TW

 

Moving my original post down here so first post can show how the truck is now & list of mods.

==========

During the current COVID-19 pandemic it has been super hard to find one of these in clean condition but thanks to spare hours stuck at home I found one in Missouri. Dealer and Carfax seem to agree this is a 1-owner vehicle and was kept in Texas and Utah so I couldn't really pass it up. Made the drive down from SE Wisconsin and traded my 2018 Subaru Forester (SF.org thread here if interested) which I am super sad about not having anymore but I know it has offroad limits and I already have 2 other cars so tough choices were made.

Anyhoo here are some quick photos to kick things off. Here's the Taco just after purchasing at what will surely be a favorite destination - the gas pump.



79,166 miles before making the drive back home. A little more than I wanted to have but I know these can last if well cared for so it doesn't bother me much.



More photos to come in next post as I begin with the baseline maintenance tasks.

==========

Stopped at a local Toyota dealership looking for washers/gaskets to do a full drivetrain fluid swap. Parts guy was very polite but frankly didn't know anything beyond punching my questions into a computer. Ended up with a few free oil drain plug gaskets but nothing else was in stock. Going to have to source online which shouldn't be hard. Used their flat parking lot to take a few more photos to share. Here's the other side angle for posterity.



On my 400 mile drive home from Missouri I noticed the suspension seems to be 99% unsafe to drive and was bouncing all over the interstate unless it was perfectly flat. First few hundred miles I was fooled by fresh blacktop but once I hit Chicagoland things got scary. Made it home safe but quickly posted a suspension question thread for opinions and people asked for photos so here ya go. Stock suspension all the way around, photos are hard to take but some have signs of leakage, others have more rusty bodies. Front driver strut here:



Rear is a little hard to see without removing wheels but all stock. Frame is pretty spotless other than the dust & dirt typical from southwestern states.



Another angle to see the leaf springs, about as good as I can do for now without removing wheels. Looks to be stock, pretty much flattened out to the overload but that seems normal from what I read on TW (also I have a 2001 Jeep XJ so no stranger to flat springs, ugh).

 

Thanks very much, excited to get maintenance squared away and start putting that 4WD to work! Lots of info on this community and trying to digest all the basic common things quickly.

 

Welcome to TW. I'm sure it was tough to see the Suby go. That was a nice looking rig you had. Have a couple friends who really love their Foresters.

That suspension doesn't sound like a fun ride. But you talked to Marie over at Headstrong and got some stuff coming so I'm betting that'll be a big help.

I'm really looking forward to some 265/75r16 tires... want to get me some Duratracs that aren't SL load rating... I'd be happy with C, definitely don't need E even if I do tow a lot!

 

Thanks, yeah was a hard day letting go of the Sooby. Was an amazing little crossover, only real concerns are longevity of that CVT but otherwise it was the best vehilce I've ever owned.

Bought my Taco with those KO2 E-range already installed but yeah for a normal DD I would have gotten a lower range for better comfort. Upside is the E range are better for my New Mexico mountain roads that will have lots of sharp rocks.

 

I always worry a bit when I'm hitting the sharp rocks with the SLs. I'm constantly running about 500 over GVWR (if not more when I'm loaded up completely for camping).

Good luck on your Elk hunt!

 

Front windows need tinting ASAP, I feel naked without it matching.



Lack of front tint makes the truck look like Gettler in James Bond Casino Royale. Bad guy look = no bueno.



Results of 20% ceramic on the front to match. Night and day difference.



Another angle to show matching front tint. No longer feel naked driving with a mismatch.

 

Stock floormats have to go. Previous owner was a smoker (something the dealership failed to tell me until after I arrived...grr) and the smell has to be fixed.



A little vacuuming, a little drill brush + carpet cleaner, a little more vacuuming. Starting to bring things back to my desired level of normal.



Husky Liners Weatherbeater (98951) going in. I've had both Husky & WeatherTech in the past and for me Husky usually fits better but just personal preference. Wish they covered more of that side carpet up the drivetrain tunnel, will have to think of something to avoid road salt damage come winter.



Husky Liners Weatherbeater in the rear. Coverage here is very good. Somewhat tricky to put in and I wouldn't remove them for cleaning without drying up liquids first (you would end up dumping right back on the floor due to how they install).

 

Stock mirror location on 2nd gen Tacos is downright terrible sitting way too low and blocking vision across the driver's line of sight.



Solution is BirdDawg Industries "Clearview-Rearview Mirror Riser". Basically a machined aluminum piece the mounts on the original location and raises the actual mirror mount up about 3". Doesn't seem like much but it makes a world of difference. Found from this thread by TW member ImMrYo who used to make something similar. Got the Ram ball attachment but not mounted here - left off for now since I don't have anything yet and removed the screws for a cleaner look.



Mirror in the new position. I don't have the "arm" fully in the upright position since it hits the sunglasses holder but it's darn close. Completely opens the sight lines and feels like a more natural positioning. Toyota engineers get your shit together.



Looks like I need a new mirror. Basically can't use the rear view mirror tab to dim nighttime lights without the mirror pivoting down on the ball socket. If I operate the tab two-handed it seems to work fine with not much more noticeable resistance than I would expect. Seems like the ball socket is just too loose and worn out. Weird, never seen that before. Guess I just have to upgrade now to an auto-dimming / temperature / compass / homelink model, eh?

https://youtu.be/7SPXdarGbQ4

 

08/05/2020: Taco fits in the garage with about 5" to spare before hitting my super low overhead door. Someday I will have a big boy garage that can store lifted vehicles but for now this will have to do.

 

Lots of things happening quickly to get the truck to pass my initial standards. Amsoil OE engine oil, severe gear

$30 75w-90 Synthetic Gear Lube - 1 Quart (Pack of 2)

75w-90, OE Denso filter, and all the gaskets/washers for the diffs and t-case. Also a bottle of 50/50 Toyota coolant for my upcoming road trip.



Another shipment from Blackstone Laboratories for future oil analysis. For now I'm going to dump diffs & t-case at suggested 30k intervals and oil I usually do like 5k miles / 6 months give or take. My average driving over past decade is like 15-20k miles a year and I probably drain things sooner than "necessary" but in the words of Bobby Brown "it's my prerogative".

 

Drained transfer case & rear diff. No photos, quite an easy job on these. Didn't order enough gear oil so I'll do the front diff later. In more exciting news I found time to inspect my shock problem - just as suspected rear shocks have given up the ghost.



New Bilstein 5160 shocks with remote reservoir. Shiny things are pretty.



New rear shocks installed. Mounting reservoir to the frame with spare tire still in place takes some contortionist moves but not too difficult. Relatively easy job all things considered.



Comparison of new 5160 shock, used half-working 4600 OEM unit, and used definitely-dead 4600 OEM unit. Conclusion = shiny one good, yellow ones bad.



Bonus gratuitous crazy sunset photo. Notice the wet pavement - thunderstorms & lightning were very very frightening while I was doing the shocks job and we got like 1/2" rain very quick. Just as I finished the sky cleared for a test drive. Shocks fixed my problems, truck now safe to drive again, and I got some Culver's custard for dessert. In the words of famous philosopher Ice Cube "today was a good day".

 

Picked up a Leer cap from a dude named Andrew (possibly a TW member but no idea on username) up near Lacrosse, Wisconsin. Color doesn't match but it seems to be a well fitting cap that should serve my needs and has the roof tracks for future kayak hauling. Photo at campsite in Juneau County Wilderness Park - not a bad spot.

 

Out with the old OEM front shocks/springs and in with the new Bilstein 6112 combo. Much larger shock body clearly apparent. Springs mounted at lowest settings for minimal/no lift. One of the OE shocks was cracked and leaking near the very bottom. Glad I did this, 80k miles on the truck so it's due for all the basics.



All installed and looking good. Of course I had to pick the hottest freakin day to do this - like 112 heat index and skeeters were tearing me apart. But it's done. Forgot to take a height measurement before install but most people on TacomaWorld notice a small lift at first and after settling in it levels to about 1/4" which shouldn't be noticeable. I do already notice how much more down travel these have.

 

Needed an actuator kit to remote lock the tailgate and keep my gear secure. Reading many threads on TacomaWorld (this one in particular) and didn't want to buy a Pop & Lock. Saw that Pace Edwards makes a kit and a company called Dyno Products who advertised a "HD" version with lifetime warranty for a bit more coin. Decided to go with the Dyno Products which turned out to be....a Pop & Lock?!?! I'm going to install it because I am out of time before this weekend's long trip but not exactly as advertised. Ed at Dyno Products got me squared away but it was somewhat painful and the ordering process is kinda janky.

Update 6/6/21: 100% do not recommend this product due to a flawed design and terrible customer service. Write up coming sometime in future. Avoid using this product!

Update 3/15/22: Finally wrote up a full product review, click here to see it. Apparently this company no longer exists and the scumbags stole my $140 for faulty products.

 

Just some basic maintenance before the big road trip but definitely worth mentioning for those people who overlook small things. Air filter was much dirtier than it looks, coming from Texas/Utah from previous owner and this one is full of fine particle dust. New Wix filter on the right.



New cabin air filter too. No matter how much I cleaned the interior it still has a lingering smoke smell. This HEPA filter was all they had at local O'Reilly's and wouldn't have been my first choice but I am a convert - this stupid little filter might be the best money I have ever spent on a filter. I think the activated carbon feature really takes the smoke smell out, almost non-existent now.



Scored some 3rd gen wheels and put onto my 2nd gen. Previous owner put those black stickers covering the exposed silver parts of the aluminum. Looks okay from 20 feet but pretty janky up close. Leaving this way for now because I've got better things to dick with.

EDIT 11/02/21: Tires were toast and went to dump. 3rd gen wheels sold off to make space in garage.

 

The Taco in New Mexico's Gila National Forest. This is all I have on my phone right now, more to come when I get around to processing the DSLR photos. Long story short is that my trip got ruined but this red-headed stepchild performed perfectly on some very rugged terrain. Identified the weakest point for offroading is the stock mudflaps - time for some more upgrades and $$$ spent!

 

Based on this thread by @stonylaroux I picked up a GQ43VT20T flip key from eBay, a USB-OBD2 cable which included techstream software, had the key cut at local stealership for $12, and programmed to my truck. Hardest part is getting the hacky techstream software to work but thankfully I do IT work by day and it's nothing I haven't done before.



Finished flip key on a quick release keychain so my house keys don't hang on my legs. Much, much smaller than factory key+fob combo & easier to carry in my pocket now. Total cost around $80 and now I can program more keys in the future.

 

Winter is coming. Truck is too clean to die a slow rusty death up here in Wisconsin so it's time to try something new. Bought an undercoating kit from Woolwax which should help prevent corrosion from the salty rust belt. 2 gallons in black + 1 quart in the default "straw" for doors and other small stuff.



Had to fiddle with different nozzles and extension wands but after dialing in the air pressures it went on pretty easy. Hardest part is just crawling around under the truck since I'm only using a pair of ramps. Came out pretty good I think and so far seems like money well spent.