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04 coil spring bucket graft.

Discussion in '1st Gen. Builds (1995-2004)' started by choopes, Nov 24, 2021.

  1. Nov 24, 2021 at 1:36 PM
    #1
    choopes

    choopes [OP] Well-Known Member

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    I actually bought a parts donor truck to replace the coil spring bucket that was damaged in a wreck last June. So far I have removed the 2.4 engine from donor and stashed it in my barn. The wreck tore the bolts off of where the upper control arm bolts to. My plan is to remove the bucket from donor and graft it onto my good truck. First I must remove both engines from both trucks for easy access. The motor had to come out first. It is removed from donor and safely stored in my barn. Rolled her down the plywood highway.
    I cut the frame, front and back, also the cross member to remove the coil spring bucket as one piece. I have been buying tools. A new angle grinder and sawzall, Thank you . The goal is to graft the bucket onto my good truck, that was in a accident last June. The upper control arm and coil spring bucket took the most abuse. Most everything from "above" is readied for the engine removal of the good truck. Tranny, starter, and clutch slave need to be done underneath. Then I pull the engine. Next the welder will come on sight here to do the graft along the same weld lines the factory used. This whole project lives or dies on the bucket being installed exactly as before. I carry the piece, now cut out, to the welder next week. I hope to get this most ambitious project done sometime early next year.

    donor truck engine.jpg
    plywood hiway.jpg
    DSC_0004.jpg
    DSC_0011.jpg
    engine lift domor.jpg
    taco parts doner.jpg
     
  2. Nov 24, 2021 at 5:59 PM
    #2
    Reh5108

    Reh5108 Well-Known Member

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    You might be able to purchase a bucket from Toyota. @Digiratus did for his 4x4. If they have them for 4wd I would imagine there's a chance they have them for 2wd.
     
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  3. Nov 25, 2021 at 1:53 PM
    #3
    choopes

    choopes [OP] Well-Known Member

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    I really did wish you were right on that. At one time. Sadly, this is the 5 lug wheel, 4 cylinder jober. I believe that on the 6 lug trucks, that is actually a bolt on part. This is a HUGE advantage, for you guys! I believe they are built tougher. If i had it to do over again, I would get the V6. Mine is made welded onto the chassis. If it weren't for the crazy price increases in trucks lately, I might have put the money into something else. Instead, I have committed to repairing this one.
     
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  4. Nov 25, 2021 at 7:15 PM
    #4
    Reh5108

    Reh5108 Well-Known Member

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    They are also welded to the 6 lug trucks frame. They are a fairly common point of failure for those who go fast on rough roads.
     
  5. Nov 25, 2021 at 7:16 PM
    #5
    theesotericone

    theesotericone Well-Known Member

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    You don't say. lol


    [​IMG]
     
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  6. Nov 26, 2021 at 9:23 AM
    #6
    choopes

    choopes [OP] Well-Known Member

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    Yikes! That is tragic!
     
  7. Dec 9, 2021 at 3:07 PM
    #7
    choopes

    choopes [OP] Well-Known Member

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    To start at the beginning. I was in a accident back in June. I got creamed at a intersection while waiting in the yield lane. I got the truck home. I realized the bolt that holds the upper control arm in place had been ripped out, warping the plate. At first I considered trying to use spacers or something to build it up, but I don't think it would track right. I spent over a month trying to find a complete frame to cut the coil spring bucket out of, but no luck. Finally I bought another 2004 Taco for a parts donor. (it means alot to donate your organs) Enter the silver donor truck. I found a welder who will work with me, and graft the bucket onto my good 04 taco. But there is a catch. He wants both engines out of both truck, and insists on welding at the same weld points as the factory welds. This should insure that it will track straight down the road, and not wear tires unevenly, after a complete alignment. I removed the engine from donor. I cut out the bucket on either side of the frame and the cross member under the engine. I have broken the tranny loose and have the engine in the good truck ready to pull.

    The night of the wreck

    truck wreck.jpg
     
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  8. Dec 9, 2021 at 3:08 PM
    #8
    choopes

    choopes [OP] Well-Known Member

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    You can see where the bolt snatched through

    control arm1.jpg
     
  9. Dec 10, 2021 at 1:52 PM
    #9
    choopes

    choopes [OP] Well-Known Member

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    I got the motor out of the "good" truck today. The next step is to get the welder over here to graft a good coil spring bucket into place. I am like a kid on Christmas. I can't wait! (almost is Christmas anyway)

    engine removal.jpg
    engine removal2.jpg
    engine out 3.jpg
     
  10. Dec 12, 2021 at 9:02 AM
    #10
    choopes

    choopes [OP] Well-Known Member

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    One mishap. The engine started to lean the hoist. I released pressure on the ram and cought it softening the landing. The engine is extremely heavy. The instructions that came with the hoist say to use it only on concrete, and not to use on grass. I leveled the plywood before I began. It is easy to get off balance. Actually dangerous . As the engine becomes free of the truck, just hanging by the chain, it wanted to rotate, by doing changed the balance. Next time i need to keep it in the same position and go ahead and let it down easy. I likely will need a strong helper at the install.

    engine removal gone wrong.jpg
     
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  11. Dec 14, 2021 at 6:34 AM
    #11
    choopes

    choopes [OP] Well-Known Member

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    Trying to get organised. I should have made notes on each electrical connection. There are many. I hope I get them all back right.

    bolts in bags.jpg
    bolts.jpg
     
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  12. Dec 16, 2021 at 11:32 AM
    #12
    choopes

    choopes [OP] Well-Known Member

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    I pressure washed the engine, and engine compartment. It looks cleaner then I've ever seen it. I am waiting on the welder. He says now that he would prefer to carry it over to his shop, 30 or so miles away. My concern is loading it. He will send a trailer. I have attached 2 tires attached as skids, but if it is 2 fold down ramps, I don't think it will work. In either case, I am at his mercy, and waiting...
     
  13. Jan 18, 2022 at 8:00 AM
    #13
    choopes

    choopes [OP] Well-Known Member

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    The welder came and picked up the truck this morning to carry back to Abbyville and graft into place a replacement coil spring bucket. He said a week. I expect longer. At long last SOME PROGRESS!on its way to Abbyville.jpg
     
  14. Apr 22, 2022 at 8:22 AM
    #14
    choopes

    choopes [OP] Well-Known Member

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    I got the truck back from the welder. Check out my "new" coil spring buckets. Now the real fun starts. I will put it all back together, with some new parts along the way!

    DSC_0001.jpg
    DSC_0002.jpg
    DSC_0008.jpg
    DSC_0009.jpg
     
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  15. May 6, 2022 at 9:28 AM
    #15
    choopes

    choopes [OP] Well-Known Member

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    I am putting the left side suspension back together. New upper control arm. Stops, a.k.a. bumpers, new shocks (front only), The Insulator (rubber piece the coil spring rides on, on top) and a power steering pressure line that goes to the rack and pinion unit. Mine got a dimple when the engine was removed. (How could that have happened?:eek: 800 or so lbs. of steel dangling from a single chain). I gotta decide whether to replace it now, or wait until the engine is reinstalled. It is difficult to get to. Maybe just put the old one in to keep dirt out, then try to install the new one after in engine is back in place. One of the fitting require removal of the return hose. Poor design!
    Rain in the forecast this weekend. I hope to finish up the suspension, then the real fun begins. Putting the 2.4 engine back in place. Transmission does concern me. It was a real pain to take out.

    bumpers2.jpg
    upper control arm.jpg
     
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  16. May 6, 2022 at 9:37 AM
    #16
    choopes

    choopes [OP] Well-Known Member

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    I am in the process of putting the suspension back together. I have been getting new parts together. New shocks, upper control arm, bumpers(aka stops), new brake caliper and hose. New insulator, its the rubber piece that the coil spring rides on on the top. I am also replaceing the pressure line that goes to the rack and pinion unit. Mine was damaged when the engine was removed. Debating weather to change it now or postpone until the engine is back in.
    Next the real fun begins. Putting the 2.4 engine back.
    Wish me luck!

    upper control arm.jpg
    bumpers2.jpg
    taco parts.jpg

    engine moved up to work aria.jpg
    moving engine.jpg
     
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  17. Jun 13, 2022 at 9:06 AM
    #17
    choopes

    choopes [OP] Well-Known Member

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    Those of you who have been following my post know what a knuckle buster of a time I have been struggling with. I finally got that sucker bolted up. Lots and lots of tried and failed efforts, finally paid off. Too many failed attempts to count. Earlier this morning the castle nut on the lower ball joint would not tighten. The whole thing was turning. So I tried to increase the pressure by loosening the tool, thus applying more pressure. Ding. The whole thing flew off. Time to start over once again. At first I thought I had messed up the threads, but it is good.
    Every time I would dig into it I would take up more ponderance of suspect parts. After all, everything got wacked pretty good in a wreck. Lower control arm bushings were suspect, so I replaced the LCA. I had already done the upper. New ball joints. Both upper and lower. I am going to put it all back together with a new brake caliper, and ABS senser. Each piece is a 5-7 day wait when ordered from Rock Auto.
    Getting the coil spring compressed was a real challenge. I have rented a tool from O'reilly's, Auto Zone, and Advance. The first 2 were just about wore out from so much use. I got lucky with the Advance tool. 3rd time's the charm. They don't work as well, after being put through repeated cycles of extreme stress. i believe it damages the threads only slightly with each extreme use.
    I don't think I want to do any more of these again. But its on there now! Check out how tight that spring is compressed!
    Notice I stripped everything off of the spindle. I tried every other way. This was what worked for me.
    This is a 5 lug truck.

    coil spring installed 6.13..jpg
    coil spring installed 6.13.jpg
     
  18. Jun 21, 2022 at 10:07 AM
    #18
    choopes

    choopes [OP] Well-Known Member

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    Installed the new shock. Gabriel ultra. They wanted $95 for a new dust cover from Toyota, so I beat out the dents with a rubber hammer, sanded and painted the old one black.
    I should have installed the stabilizer bar before the coil spring. As much trouble as it was, I had to compress and remove the big spring, mount the stabilizer bar (aka strut bar), and put it all back. You live and you learn. I thought I would never get the tool out of there! The upper control arm was mashing on the bolts. The trick is to drop it down one link in the coil. Its all in there now. Yahooo!

    new shock.jpg
    dust cover.jpg
     
  19. Jun 30, 2022 at 9:30 AM
    #19
    choopes

    choopes [OP] Well-Known Member

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    Work is coming along. I need to bleed the brakes. I had to order a replacement stabilizer bar (AKA sway bar, AKA anti sway bar) from a overpriced online salvage yard. It should be here Wednesday. Just a week or so shy of a year. FINALLY she'll have 4 wheels under her again. No longer a 3 legged dog!

    LF wheel w brake.jpg
    LF wheel w brake2.jpg
     
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  20. Jul 14, 2022 at 8:10 AM
    #20
    choopes

    choopes [OP] Well-Known Member

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    I used my motor hoist to pick up my engine and lower it into my 04 Taco. Motor mounts not lining up. Well, one is. I may have to pick it up again a inch or so and try again. Then a hard rain came.
    Those who have followed my posts know the problems I had with the accident a year ago. Lots of problems getting everything together and rebuilding the LF suspension. The first alarm bell I got was when I tried to put the sway bar(aka anti sway bar, aka stabilizer bar) on the truck. It didn't line up right. This is the bar that runs from LF wheel to RF wheel. I actually ordered another one from a salvage company thinking mine was damaged in the wreck. It wouldn't bolt on either. Then. My worst nightmare! Measuring the wheelbase. I now have 4 wheels on the truck again! Left side from front wheel to back is about 1 3/4" longer then the right? Yikes!
    When I did the front wheel I changed upper control arm. Tie rod ends. Upper and lower ball joints. Stabilizer bar from the donor truck. I ordered a new LCA from parts geek. I spent several days trying and trying to install it. Finally I noticed the brake line fastener made onto it was on the wrong side! I had a right side LCA. I was so PO'd, I put it back together with the original LCA. I compared it carefully to the one out of the donor truck. Both the same. No visible damage. I wish now I had used the donor LCA but it is a solid mass of rust, having come from Virginia.
    I need to find someone with a frame straightening machine that can pull it back. There is one shop that does that where I live and he doesn't seem too interested in helping. I thought about trying to pull it myself. I wonder where to pull from, and where to anchor to. At least if I can finish the engine install, I will be mobile. Surely I can find a shop who will do this for me. I don't know what's wrong with these shops around here. I suspect they only want to do the big jobs for bigger money.

    motor back in truck.jpg
    motor back in truck2.jpg
     
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