2003 4Runner Limited 4wd V8 FJ tcased overlanding rockcrawling do-it-all build

So a couple quick points, but certainly do your research and do what feels best to you, read through both these threads though. Your front diff tube is full time currently and is designed to be engaged all the time, as is the one in the AWD FJ. Many folks have been running the FJ case with no ADD without issue, but I do agree that Toyota does not send a vehicle out of the factory equipped like that. Non-ADD is stronger, less parts and no motor to fail, you also already have that in your truck so less cost and effort to install, particularly with the ADD switch wiring.

https://www.tacomaworld.com/threads/lets-see-your-fj-case-swap.455278/

https://www.tacomaworld.com/threads/how-to-deleting-add-system.427258/

 

Reading thru these threads now that I'm back home.

My concern wasn't for the front AWD axle but more for the FJtransfer case. Leaving that in 2wd while the front axle is still spinning the front driveshaft won't cause any damage to the transfer case? That is what RST is saying, I think.

You were correct on the FJ cases being cheap. It's interesting the the 6spd FJs were AWD. I guess technically I could go that route but part of the point of doing the swap is to get the ability to go 2wd and have the 2wd low option. I've had many times where that would have been handy.

 

Further research on the FJ 6 speed AWD cases shows that they are not viable for the swap. They can't be made to work at all. So the only option are the auto t-cases.

On another note, I have new OEM seat bottom foam on order for the driver seat and placed an order with leatherseats.com for a complete seat upholstery replacement kit. Changing the color of the seats as well, going to a black and graphite color. Need to find a good paint to change the color of the seat plastics now.

 

I don't think it would be an issue, I imagine the front shaft bearing/support is similar between the AWD and part time case, but IDK. A bunch of people on here have done this without issue, but YMMV as always.

The AWD FJ case should be the same as yours, but if you are swapping cases I would lean towards one with a manual shifter to rid yourself of the issues you are currently having with the shift motor.

 

AWD FJ case is a no go, it won't bolt up at all.

I was thinking about how the ADD axle works and I now kind of feel like what RST is saying about requiring to use on for the swap is BS. The reason is that the ADD disconnect is on the passenger side, which means that the driver side, even in 2wd, would still be turning. This is how the setup was with my 1st gen Taco as well. So the front driveshaft will still be turning all the time, even with the t-case in 2wd mode. I think the FJ with auto trans has the same front ADD axle as the Tacoma as well.

So yeah, that's why I think I'll be fine with the AWD front axle I already have in the truck. Good call @Wishbone Runner!

 

Work in progress while I wait for the replacement tcase actuator. Still working on sourcing a FJ tcase too.

I made a cardboard template. Have maple faced 3/4" ply that I'm going to use this to cut. It'll be a base plate for a cargo system when I'm done.

 

Transfer case leak is fixed but the actuators still don't work. Got the replacement housing today. Managed to crack the top of the housing by being dumb. But I need to be able to drive the 4runner again so slapped it back together. The damage isn't bad enough to worry about unless I do a water crossing. But that won't happen soon as 4lo and the center diff lock still don't work. I've given up trying to fix it now. I'm just going to hunt down a FJ transfer case and do that swap.

 

Found an FJ case for $269, should be able to pick that up locally Friday.

Rest of the parts are coming from RockSolidToys.com. Should take about a week or so before they ship. Depends on the front axle if they have to source one or have one with the right gearing. That was the cheapest part too!

Sourcing the tcase myself saved me about $870 over getting a complete kit from RST. Highly advise anyone wanting to do this swap try to source at least the tcase yourself. They can be found for around $300 on car-part.com. Front axle was scarce so I got one from RST. They sell those for only $150 so it's a no brainer there.

Also got a call from the guys at leatherseats.com. They are sending me color samples just in case but the guy actually sounded excited to see the 4runner once I was done. I find that pretty cool that they are actually excited to see the final results of their products.

Shit will be getting done soon!

Drove the 4runner to work today. No visible leaks from the actuator housing with the new o-ring and shaft seals in place. 4lo and the center diff lock still don't work but I can drive it for now at least. And I still have 4wd, so there is that.

 

No, it won’t. The axle shaft will simply spin the spider gears all the time but that’s it.

@Wishbone Runner why do you say the non ADD diff is stronger?

 

Yeah, I've already talked with RST on it and some other people. I'm going with the ADD housing for the swap.

 

That will enable you to have 2lo without twin sticks by shifting the xfer case into 4lo without engagement of the ADD.

Just be check first if your V8 oil pan clears the ADD

 

FJ case with twin sticks will give me 2lo as well. Oil pan gets modified to clear the ADD housing. It's part of the RST kit so I don't have to mess with it and gives me a spare that I can modify later if needed.

 

Not the diff, just the tube and "axle" in it, less parts and one solid shaft.

 

Does the RST kit include the ADD tube and parts?

 

Yeah, a complete ADD axle and they supply the wiring harness to make it work. Along with the modified oil pan for the V8 to clear the ADD housing. They only charge $150 for the front diff too. No brainer there.

 

So uh. I take it this will all be installed next week?

 

Well, sure but then you will have a diff that spins all the time in 2wd including the drive shaft and the chain in the xfer case. Unless you also want to get manual hubs which IMHO is a shit idea on these trucks.

 

The awd clamshells (at least on 5th gen runners.) don’t have the needle bearing.

 

Lol, I wish! I'll be lucky to have all the parts by the end of next week. RST said it could be at least a week before they get the parts shipped out. They need to verify they have a front diff for me and also modify an oil pan.

Info on the swap for anyone interested. - https://www.rocksolidtoys.com/single-post/2017/08/19/4RUNNER-FJ-T-CASE-SWAP