2005 DCLB PreRunner Build

I've never done a build thread before, but then again, I've never had a community that wouldn't prefer heckling you to death.

Thank you for that by the way.

So I bought this old girl on February 1st, 2020 with 196,000 miles on the clock.
2005 DCLB PreRunner SR5 V6. 2WD wasn't my first choice but Tacomas here are harder to come by in this configuration and aside from that almost all are ragged on in the desert, 2WD and 4WD alike. This is one of the few that wasn't.

One owner from new was an older gentleman who didn't do anything to it beyond regular oil changes and the occasional air filter. It was traded in to my friends dealership and I got first dibs. Unfortunately it didn't come with any maintenance history but I'm pretty sure most of it is original anyhow so I'm just planning to replace it all over time.


The day She came home.


Got snow a few days later, that's a rare occurrence here.


Replaced the windscreen. We have a 0$ glass deductible for our Jeep and just mirrored the whole policy over onto the Tacoma, absolutely worth it.


Ditched the chrome.
You can see the quality of the roof paint in this one ^ The green tape from the windscreen replacement took some paint with it when it was peeled off.


Got the side steps off a trade in at the dealership I worked at. Got front seat covers as well and swapped the complete back seats and sun visors too.


Ordered parts. OEM blower motor resistor kit, Dobinsons grease-able pin kits (SP. 59_06_0) x2 pair, Spicer grease-able U-Joints (5_1330) x3. More on the way.



Replaced the blower motor resistor. Blower works proper now, recharged the A/C as well. I have a leaking schrader valve on the low pressure line that needs replacing eventually.

More parts!


Found a great deal on the NitroGas Stage 2 kit from Ironman4x4America , looks to be well built stuff.


Rear done up.
I have +4" SS brake hoses for front and rear from Low Range Off-Road, those will go on when the front is back on the ground. I also installed new shackles from 4xInnovations, came with new poly bushes and zerk fittings.
Slapped on some F-150 Gatorback mud flaps for kicks. Not too shabby, but we'll see if they stay.
I ordered some bleeder screws from Speed Bleeder too, the long ones. I didn't go with the stainless steel, it didn't seem necessary. Time will tell.
FRONT - SB7100 (M7 x 1.0)
REAR - SB1010 (M10 x 1.0)
Got those from rallysportdirect, they had cheap fast shipping.


Prepping the bushes for install.


Yes that jack is as precarious as it looks. It's barely resting on the blocks under the rear.

Pulling the LCAs, just about zero rust anywhere underneath. The benefits of a desert vehicle. Not something I ever had growing up in Ohio.


Bought a proper jack and stands. Those are not the recalled stands, confirmed with HF customer support. Not that I get underneath there anyway.


Both front struts and rear shocks were leaking oil. Those strut bushes though, a little off center.


The extent of my rust woes. So far at least.


After slapping it around with some steel wool.


Out with the old.


In with the ne...wait that's... that's backwards. Nuts.

SIDE NOTE: pay attention to the instructions for the Whiteline bushes, thicker bit of poly to the outsides of the control arms. I bought the (W) 533. 12 kit, no fitment issues. Just install them properly.

It was destroyed getting it back out because I'm an idiot sometimes. You can definitely get it out clean with the right press. Whiteline stood behind their product and sent me a warranty replacement set.


I cannot wait for these to go in, at this point because it'll mean I'm done. Finally.


Replacing the sway bar links too.

That's all so far, I'm waiting on those replacement bushes and then it'll all go back together. I'm going to have a shop press those bushes in.


Bushes in the right way.
I didn't end up going to a shop, I had a hand from my Father-in-law and his friend who has one serious vise. Still sucked but they're in.


Pulled the steering rack.


Set up the tie rod ends.


Old steering rack bushes out.


New Energy Suspension rack bushes installed.


You may notice in this next picture that there are more threads showing than on the passenger side, and maybe you've zoomed in and noticed the bushing is curved up a bit. That's because I over torqued it, a lot. It ripped the bushing. I'll have to get a replacement set eventually, I'll see how it rides for now. Whoops.

This bolt...
This was by far the worst part of the entire project. I moved the A/C compressor because I wasn't about to try wrangling a hacksaw up in there. No thank you.
I have reinstalled them the non stupid way, with the nut on top. Bold statement you say? Well maybe, but I am confident in my choice.


Ran to the local nut and bolt shop, took some measurements anddd...


Try falling out now.

The eye on that cotter pin is a bit large, I'll have to find a properly sized one and swap it out.


It was a hot one today, supposed to be like this all week. I sucked it up and worked until three but dagum, all my stuff kept burning my hands.

We'll see how it goes, it isn't that bad in the morning. Hopefully I can jam and get most of it wrapped up tomorrow.


Almost there, just need to load it up and torque to spec.


Looking pretty good, the alignment cams lined up nicely.


Finally back on the ground!


Baby shoes!


Driveshaft time!


Spicer parts; (Universal Joints - 5-1330 x3) (Carrier Bearing - 5002334)


Annd once again I have to stop and order another part. Look closely at the flange on the left side, the retaining groove for the spring clip is blown out. It was hanging on by about 1/2 an inch of what was left.


Better shot of the damaged flange. New one is on the way, Spicer part, 5001905. Ordered from Drivetrain America.

I have no idea how long I was driving around like that. The rear u joint had been replaced before I bought it, I would guess the "shop" who did it was sketchy.
Just hammer it in they said, it'll be fine they said...


This yoke will not budge, I soaked it with PB all day and still nothing. I'll probably need a shop press, again.
Adventures for tomorrow.


Looks surprisingly clean for being so seized. I guess we'll see what the spines look like. I forgot the nut and smacked the end, I'll have to file the threads just a bit to smooth them back out.

Used a press to get the yoke off, the splines were rusty. I didn't get a picture of that before I put it all back with the new carrier bearing. Finished installing the u-joints and the new flange.


Installed. Hopefully I don't get driveline vibrations now. I may need to have it re-balanced.


Prepping for brake hose install! Which basically entailed taking them out of the package. Quick, simple, easy.


Yikes!


That's better, a little breathing room.


Rear driver's looking good, passenger not so much.


This little bugger, the only flare nut that didn't come loose. I started soaking them all with PB a few days beforehand but this one decided to round over anyway. That bracket location sucks, unbolting makes it easier to access.

I'm just replacing that entire line, it links up just below the driver's door on the frame.

At this block.
I can get the line from Toyota through a friend at Ford for 37$.
I would rather replace the whole thing than try to cobble a "fix" together.
Those two brake lines are
47325-04180 and 47326-04150.

43$ with tax.


The old one was a little tough to wrestle out, ended up cutting in three pieces. The new one is not routed through the original locations, because of the angles I would have had to drop the fuel tank to get it in there. No thank you.
Just zip tied to the frame, with the proper clearance from angry and abrasive things.

That's all for now.

I'll update as I go.

Thanks for checking it out!

 

Nice truck. You put in some work on this one.

 

Black DCLB's rule!

 

Thank you! I was happy to have a project again. The truck is a change of pace from my usual suspects haha.

This baby is sporting a gloss black metallic and plain black roof with no clear coat Juarez respray special, no prep except taping off the glass.
Rough around the edges but it looks good considering.

 

Man, that's awesome! Great project truck, after you're all done it should handle like a dream. Hopefully not like your mustang ever did, and more like the Trail Blazer. Keep it going man

 

More like White ,Black is the worst color you can get for driving in the southern states,hot as hell.

 

Thank you kind Sir, that is the plan!

YES. Good heavens they get hot.
I did not have much of a colour choice in this case. A sunshade mitigates a lot of that interior heat.


Thankfully I have a carport to park under while I'm working on it.

 

@rutabega_101

Updated.

I know this is in the wrong place, I have reposted it in the proper subforum. I will keep it updated here as well though.

Here:

https://www.tacomaworld.com/threads/2005-dclb-prerunner-build.669868/#post-23512258
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Apparently there's a message size limit.

So here goes the rest.

Bled the brakes, flushed the whole system. Speed Bleeders are amazing.
I let the master cylinder drain out too much fluid when I removed that line so I had to bleed that too.


Ran a line from the front driver's caliper through a convienently placed hole in the wheel well.

Up to the reservoir thereby creating a closed loop to bleed the master cylinder. No bench needed.


I've also swapped the zerks on the 4xinnovations shackles for a 90 degree so I can actually get a grease gun on them.


That's all for now.

I'll keep updating as I go.

Thanks for checking it out!

 

To be fair, the Mustang is 20 years old.

 

Update!


Replaced the center console latch, mine was holding it closed but was missing the spring and the housing wouldn't retain the button portion so it kept falling out when I opened it.


Easy cheap fix for 12$.


Patience is a virtue!
I started my cap search the week I got the truck. Short bed caps are plentiful and I found loads of them.
I almost settled on a silver A.R.E. off a Ranger about two months ago but decided against it.


Found this locally yesterday and picked it up this morning for 325$.


No broken glass, everything mostly works. I'll just need struts for the rear glass eventually. Plus it already matches!

 

The idea was to be able to load up quick Friday afternoon and make the mountains before sundown.
Easily loading provisions for two people and one fuzzy butt.


I started taking the seats out to measure for a platform but when I folded the backs down they were pretty flat.
I took some measurements to see if his house crate would fit. No sence buying or building something if this will slot right in.


The butt.
He hates camping, doesn't like being outside at all. If he had a bathroom inside he'd never leave the house.


A few straps on the back and bottom and we're all set!
He'll have a view up front, and we can roll down the window for some air.
We can also open the slider when we're in the back and he'll be right there.


I'm working on plans for a platform, I'll post up when I get it finalised.

 

Got the Maint Reqd light yesterday.

Y'all needed a picture of that right?
Somebody wiped down the dash with acetone or something they shouldn't have. It isn't that bad to see through but I'll address it eventually.

The oil sticker from the dealer was still within the date and mileage but I changed it anyway. It was dark but not black. New drain bolt and washer. Pennzoil 5w-30 full synthetic and an STP gold filter or whatever those are. Extended life maybe?

I've used Pennzoil my whole life. That's how Dad does it, and it's worked out pretty well so far.
I did not take pictures of the oil change, I'm sure you've seen that though.


I started the wire up for the third brake light on the cap. This is how it came.


There's a small gap at the top that feeds right into the taillight area.

Like so. I thought my wires would just fit through but I ended up drilling a 5/8 hole in that spot for better space.

I picked up these. I do not usually like quick splices but they were indeed quick and it works. I didn't want to fully cut the harness.


Split for the splice!

Twist, and

Twist again.


Dab of dielectric grease and heat shrink. I taped the extra connector wires together for now and wrapped it all up.


Spliced into the green and white for power and black for earth.
There was a hole in the cap already that fit a zip tie just right.

I got the 4 terminal connector so I can wire up some overhead LEDs in the cap later on.

Works just right!


That's all for now.

Thanks for checking it out!

 

Took advantage of that fancy insurance we've got and had them flatbed it to the shop for an alignment.


Off She goes! We just met them there.


On the rack.

It was halfway sort of okay! The screaming tires on the test drive the day before would tell you otherwise though.

 

I did spark plugs today!

Finally an easy job!
I did have to go get another 6" 3/8 extension because I couldn't turn my retchet enough with just a 6" and 3".


But then...

And then...


Well this is less than ideal.


There is an odd man out here too.

#2 is an Iridium

$39 LFR6AIX-11 - 6 PCSNEW

LFR6AIX-11 while the rest are

$6 LFR6C-11 V-Power Spark Plug, Pack of 1

LFR6C-11.
#2 was also the only one without oil on it.



So I guess valve cover gaskets and/or plug tube seals are now on the list.
That's for a later time, but not too much later. Catch 22.

I also changed the rear differential fluid.

MasterPro 80W-90 x3
It was the only dino fluid AutoZone had so in it goes.


New crush washers from Toyota too.

I did not go with synthetic because my seals are old and I don't want to deal with that potential mess right now.
I do not expect any viscosity issues during the West Texas summer. Or at any point out here really, I mean, come on.

It was cheap enough this time around that I don't mind changing it to synthetic when I do the seals.

 

Here are fluid samples if anybody is interested in that.

Engine Oil:



Rear Differential Oil:



Neither looked that bad, but now I know when they were last changed.

 

Pulled a wheel to get the # castings off the back, found this thing.



I picked at it a bit, feels like metal.

Opinions?
Sketchy balance weight?
Hole in the rim with a super sketchy "weld" repair?
Just a blob?

I guess I'll know eventually when they run the old tires off.

 

Ordered new tires yesterday, Cooper Discoverer AT3 4S in 265/75r16, x5.
Went and had them installed this afternoon.

After lots of discussion between the forums and local people here I settled on the AT3 4S because of the capability, great reviews and ratings and weight savings versus an E load. 42 lbs to my then current 40 lbs highways. Not to shabby.


In the shop!

Staging to run them on.

Installed!
Still looks high, probably could have done 33's!
I did some circles in the parking lot, no rubbing to be found. I took it up over a few inclines and angles to check there too. No rubs.

A couple of my center caps broke so the shop is going to order replacements for me.
Walking back out after everything was all buttoned up I took a closer look at the tread and then I saw it.

That looks like it says LT, because it does say LT. Those are AT3 LT's, not AT3 4S'.
Well nuts.
I talked to the shop again and checked the specs on the LT variation. "Looks like the wrong ones were ordered" they said.
I'm just going to roll with them. They are C load, still 265/75r16.
48lbs each, one pound savings from the E loads, 8lbs over what I had. So much for all my research.
We'll see how that impacts the mileage, I don't imagine it'll be enough to make me cry or anything.


They look pretty good! Something tells me I'll be hearing more rocks pinging off the undercarriage!

 

Got her on nice level ground this afternoon, got a bit of rake going on there! It's just backwards

Skid plate recommendations anyone? For weight .

 

So far the Ironman kit is performing well!
Took it up to the mountains this weekend and hit some trails. I don't have an air compressor yet so I'm just running street pressure and even with that it's pretty darn smooth over the rough terrain.
I will post pictures later.

But wait! The most important part of the trip so far is that as of right now we are stuck in the middle of the woods with a truck that will not run. Yes, I have one bar of service and I'm using it to talk to all y'all.
Turns over, sometimes, other times I just get a single click sound. When it does turn over it'll struggle to run for a few seconds and die.

I have gas, 3/4 tank. No codes. The stupid gulf states alarm is disabled, I think.

Could I have loosened up some crud in the fuel tank bouncing around off road and gotten something sucked up into the fuel pump/sock filter?


EDIT: We made it home!
Pictures of the trip!

Watching the rain roll in!

 

Well we "ceased to have a proper ignition sequence" at a designated camping area and we're just outside of town so we have signal for our mobiles thankfully.

When in Rome


I'll try it again in the morning after it's had time to settle and if it still won't start up we'll just have to tow it.