Another PreRunner 4x4 Conversion Thread...my 2004 Build

Guess I had my original thread in the wrong section, so re-posting here.

Hey everyone!

A few months back I posted my first thread here on whether to 4x4 swap my 2000 Tacoma PreRunner:

https://www.tacomaworld.com/threads/should-i-build-it-or-sell-it.705535/

However fate happened and I ended up finding a crazy clean 2004 Tacoma PreRunner with 124k miles and a V6 for a killer deal. I sold my red one and am so happy I did. The 2004 is just a much better platform with the V6 and the newer interior is more comfortable than my old 2000.

I got the truck from the second owner and it was maintained at the local dealer it's whole life. Recent work includes the timing belt and radiator as well as some other stuff.

Here's a pic from our first trip up to my parent's place in northern AZ.



I'm dead set on doing a 4x4 conversion and also some light mods to make this thing exactly what I want it to be.

Plans:

-4X4 conversion with manual locking hubs & j-shift transfer case
-OME 883's & Dakar Rear leafs
-ARB Bumper w/ Warn Winch, IPF lights
-ARE Camper shell
-265/75/16 tires on stock rims (for now)

The truck is my daily, but I do like to do a lot of camping trips and want to do even more. I've already started stockpiling parts for the 4X4 swap and am almost done. I'm replacing every part I can while I'm in there so I don't have to mess with anything for a long time.

Here's a list of everything I've bought for the 4x4 swap so far:

Front Manual Hub & Bearing x2
Aisin Locking Manual Hubs x2
CV Axles x2
Front Wheel Seal x2
Front ABS Rings x2
Wheel Bearing Seals x2
8mm Hub Hardware Kit
OEM Tools Hub Locknut Socket
Shifter
Front Diff
Front Diff Brackets
Front Diff Drop
Front Diff Manual Hub Tube (w/o ADD)
Transmission Output Shaft Swap
New OEM Ball Joints (Upper & Lower)
Donor Tranny (taken apart for output shaft & tail housing)
Front Driveshaft
Rear DriveShaft

Still looking for a J-Shift transfer case, but think I have a line on one. I'm going the route of converting my A340E transmission to an A340F as all the used 2003-2004 A340F's I have found either can't have verified mileage or have shavings in the pan and they still want $800+. I know for a fact that my transmission is good so I'm more than happy to reuse it.

I've already gone ahead and ordered the ARB Bumper & my OME lift from Wheelers. I'm going to be installing the lift first as it'll give me some more room to work with when I'm dropping the trans & installing the front diff. I'm also going to go ahead and re-seal the oil pan while there's no diff in the way since I'll be there.

Anyway - super excited to get going on this build and can't thank TacomaWorld enough for all the info on doing this swap.

 

As I've been piling up the parts needed to do my 4x4 conversion, I ordered my ARB bumper and an OME lift kit with the 883 coils & rear leafs. I figured that I would lift the truck first as it would give me more room to work underneath it to get the tranny out, as well as being able to have the truck on all 4 wheels while I do it. Ordered the stuff through Wheelers Off Road and less than a week later I had this giant box show up!



I got the bumper and crush cans off, and started the task of putting the ARB together. I've heard the instructions are extremely terrible, and they are. Took me a few hours but I was able to get it on and I have to say it looks great.



I haven't bought a winch yet - that will be down the road with the lights. First mod - complete!

A common problem on these trucks that I've seen is the passenger air vent either being broken or completely falling apart. When I bought my truck, the vent had broken and the previous owner Mcgyvered a spatula into a vent...needless to say that had to go.

You can buy the vent new from Toyota, the part # is 55660-04030-B1. There's not much online about replacing it, but it's really not that hard to do. The only post I found on the subject said that the airbag had to be removed. Well, I'm glad to say you don't have to. It is a bit of a PITA, but you basically have to remove the glovebox & the top of the glovebox, then remove the air duct behind it and that connects to the vent.

Then there are three phillips head screws that you can remove to get the vent out. One is on the far passenger side of the dash and it is a PITA to get out, but can be done with a stubby screwdriver and some serious contorting of your arm. I did not put that screw back in because well, I couldn't even get close to getting it started. Plus I figured if I ever have to replace the vent again it'll be a much easier job.

Here's the old spatula vent and you can see how it mounts.



And the new one in place:



I just got the OME lift kit last weekend, and am going to be throwing it on this weekend since I have Monday off. More pics to come!

 

Since the parts are all about, I'd suggest replacing the bushings in your diff mounts, and install a front locker if you plan on running one at all.

 

Solid advice! I'm trying to replace as much as I can while everything is out. Any aftermarket kits that are any good or should I stick with OEM?

Nvm - did a quick search and found DuroBumps. I'll go with theirs!

 

Add Durobump stops while you're at it; dropping off ledges/steps is so fun having a set in the front and rear.

I ran Wheeler's bump stops in my Tacoma when I had it, but run Durobumps on my 4Runner.

 

Got my OME lift kit installed and some Goodyear 265/75/16s on as well. It sits a little higher than I thought I would, but I'm hoping that the weight of the camper shell and bumper will help it settle. The truck is starting to look like the part of a 4x4 - now it's time to make it one.

 

Springs settle; you'll lose between 1/4" to 1/2" more both front and back with some mileage.

I had a Prerunner as well with an ARB and had pics of the initial and settled heights with various weight added; settled in just nicely.

 

When I bought the truck I always wanted to put a bedliner in it because the bed has seen some better days - it has lots of dings and dents inside of it. I was extremely surprised that I was still able to buy them brand new from the dealership!

 

So the 4x4 swap has officially begun!



Since I'm running manual locking hubs, I removed all the ADD stuff on the front diff and swapped over my manual locking hubs diff tube. It was pretty easy to swap over, except getting the small shaft for the ADD out was kind of a pain. I was lucky enough to be able to get it out with two prybars.




I also installed new OEM CV shaft seals on the diff before installing it:



And then up it went into the truck with the differential drop. It fought us a little bit, but finally went in!



I took the spindles off to get the bearing & hub pressed out and my new manual hub bearing/hub pressed in. Took this time to install the CV axles too as I couldn't wait to get them in.



Once I get my spindles back I'll have the front end all buttoned up and ready to go!

 

Are you planning to do an elocker? Also what is your gear ratio?

 

E-locker is definitely in the plans - but that will be way down the road.

My truck currently has 4.10 gears- verified by the dealer and the vin tag!

 

I was asking this question because I am adding the elocker in the 4.10 gear ratio and of course I am doing the front as well. My truck came with 4.56 from stock. Which gear is in your opinion better?

 

It depends on what you want to do with the truck. If you're planning on running it stock, the 4.10's are fine. Even on the slightly larger 265/75/16" tires my truck gets along pretty well. If you plan on going to like, 33"s or larger you may want the 4.56's.

 

I am running LT 275/65R18 on a 3 inch lift with the e-locker diff. and the 4.10 gear ratio. Pretty much stock use . No trails or 4X4'ing , occasional towing for supplies from home depot or lowe's ,Tractor supply. So, I should be fine. I like your conversion, looks like fun work. great work there! Thumbs Up!!!!

 

Got my front spindles back from the shop, had them press in a new wheel bearing/hub, upper ball joint & seals. Everything is looking good!



Installed the new spindle along with a new OEM LBJ and new LBJ bolts. Threw a little bit of red loctite on to ensure the LBJ's are good to go. Torqued everything to spec.



And finally for the best part - I installed the brand new OEM locking hubs. Everything went together really easily, and I was able to press the manual locking hub stuff into my PreRunner spindles with no problem. I also kept the ABS as well and everything is working as it should.

Now onto the transmission and transfer case!

 

I got my brand new ARE camper shell installed on Friday! Really amazed with how close the color match is.



I also made a quick weekend trip up to the White Mountains to meet @KingOfTheNorth who was nice enough to pickup my transmission in Salt Lake City. I was originally going to pull mine and have a shop swap the output shaft and tail housing - but I found a great deal on this tranny/transfer case out of a 2002 Tacoma from @vonellis . The transmission has under 100k miles and will keep the down time on my truck to a minimum.



The only issue is that it is out of a 2002 Tacoma - and mine is a 2004 with the electronic throttle body. To fix this, I will have to pull the pans off of both transmissions and swap the valve bodies. Then my 2002 transmission will be ready to roll in the 2004!

 

Good to meet you! Glad I could help out and it all worked with timing.

And Sub'd to the build!

 

Nice to meet you too man! Can't tell you how happy I am everything worked out!

 

now get to work!

 

Nice work. Subbed along with my many other conversion threads. Hopefully i'll get mine started and done before its 20th bday.