'06 Prerunner conversion to 4x4

Me too! This thread (with pics) is going to be awesome! Maybe do a write up?

 

I installed the front differential last night. I had many other names for it while trying to get it in it's spot! Pictures below. You have to take the guard off first to see where you will be mounting to.

I will upload a parts list later this weekend. I plan on doing the front hubs and axles this weekend.

I believe most of the mounting bolts are 19mm and 22mm. There are some smaller bolts for the brackets that hold the breather lines and the actuator in place. My front differential came with the actuator so that saved $270 (PN 4140035031). I bought all of the mounting brackets, bolts, and other stuff from toyotaonlineparts.com.


I changed the oil seals because one was damaged. It is better to attach the rear support (one near the drive shaft flange) to the differential before installation. I used a ratcheting strap to hold it in place while I bolted the other supports in.


These are the drawings I used for part numbers.

 

Inspirational, really digging this build.

 

For living in Pennsylvania, your truck is very clean underneath. I can't wait to see this come together. If for no other reason, other than having a 4X4, this conversion would be great just for the challenge of it.

 

Oh... South Carolina, even still, very clean!

 

Nice write up..by the way what were the names of the front diff?? Lol

 

That is one reason I decided to do the conversion over trading in for a 4x4. The ones I looked at up here were not in good shape.

We are on much better terms today. Lol

I managed to install the hubs and CV axles today. The first one took a while. My rotors were being stubborn. I finally figured out that you can use the 12mm bolt that holds the ABS cable as a push bolt to break it loose. Then getting the CV to lock in to the differential was a little hard without a slide hammer. I found that it was easier to push it into the diff as far as it would go (still had about 1.5" to go) then go ahead and put the other end into the hub. I put the nut onto the end of the threads and tapped it with a hammer and I used a ratcheting tie down strap to pull it in to place (pic below). You can tell when it pops into place. Filled the diff up with a little more than 1.6 quarts of Royal Purple 75W90. Ahh the smell of gear oil!

You can see the threaded hole that you can use to push the rotor off after taking the caliper off. It is to the left of the caliper.

Old hub off.

New hub that was ordered from Kevin.

This is how I got the CV to seat. That ratcheting strap has come in handy!


I am not sure when I will be able to finish it up. Still waiting on the transfer case. I will hopefully get it next week. I will then be able to measure everything and know how much to chop up on my drive shafts. I should be getting my modified crossmember next week also.

 

Sweeeeet! Are you still driving this truck while working on it or do you have another vehicle you're driving until your truck is finished? I'm hoping that with all of the research I've done and builds I've read that I can have absolutely every part I need, all the way down to the bolts, so I can do the whole swap in a weekend and drive it to work Monday morning.

 

Yep, still driving it. My plan was to do it in one weekend but I had all of the parts for the front so I decided to go ahead and get started. We moved in to an apartment so I was running out of room to store everything and my wife was getting tired of them sitting around. I am doing all of this in a one car garage at my apartment building. Once I get everything else I will get it done in a weekend or one day hopefully.

 

Can't wait for outcome, I want a manual transfer case so bad

 

Exactly how I plan to do mine. Install everything for the front one weekend then install the trans and t case the next weekend.

 

On those CV axles, I've read that if you turn them about 1/6 of a turn and push (repeat as necessary) they should slide in without too much force. There's a clip that lines up with a groove or something like that. No experience here, just what I've read.

 

I struggled with the first one for a while trying the turn method. I noticed that some people use a slide hammer but I don't have one. I am sure technique plays a part.

Thanks for the advice! Might help someone else in the future.

 

4x4 won't help you commute, except if the objective is to overdrive the conditions and end up in a ditch. Throw 2-3 sand bags over the rear axle for a little more grab, and a set of good tires. The limited traction will help keep you from becoming overconfident and following the path that leads to the ditch.

When winter comes, pay attention to what vehicles you see in the ditch. There are two specific things you will notice; teenagers (overconfident by design), and 4x4's (overconfident by vehicle).

The problem is that 4x4 helps to make you GO, but does absolutely nothing to make you STOP.

 

I understand there is technique involved and 4x4 is not a cure-all, but you can't tell me I am better off with a RWD truck than a 4x4. However, a debate about 2x4 and 4x4 in the snow is not really what this thread is about. The first paragraph of my initial post was just a back story. My intentions for this thread is to help others who are going to make the conversion in the future.

Now, the parts list for the installation of the front diff. I hope it attaches okay. I think this is all inclusive if you have the actuator on the differential you are going to install. If you have the mounting brackets then it will be less parts. The only other parts needed for the front would be the hubs, seals, and CVs. The hubs and seals I bought from Kevin on here and the CVs came from summitracing.com. I believe rockauto has them as well.

Let me know if I am missing something and I will modify the spreadsheet.

 

I am beginning a conversion process as well... I thank you for your parts list on excel OP. Let me know if you find out any short cuts/ tips...

 

Very cool! Good luck with the conversion... It may open up a whole new world of things to blow your money on

 

It seems like once you go from PreRunner to IFS 4x4, it's not long before you go SAS lol

 

Will do. PM me if you have any specific questions. Are you using the inchworm adapter or changing the transmission? I should be receiving the transfer case, sticks, knobs, and wiring harness on Thursday. I am going out of town this weekend so I won't be able to get it installed this weekend. But That is my project for the following weekend. I have to finish it before I head south for Thanksgiving.

SAS isn't on my list It gets very pricey. I don't plan on doing an extreme amount of off-roading so I will just go with a minor lift (2 - 2.5" in front and 1.5 - 2" in back maybe) and 1" bigger tires. I don't want to have to do UCAs, diff drop, or other mods there. But @avw4x4, yes I do have a list going!

Any recommendations on the lift?

 

Who doesn't ? The electronic never seem to be as quick and concise. I miss mine along with the manual hubs.