LFaub's 4x4 conversion/camper build

Big weekend here at my shop! Lots of fun stuff, y’all already know what’s going down!



Dropped the ol’ 2wd transmission




So since I bought an ‘02 donor transmission, it had a mechanical TV cable, so I had to tear apart both transmissions to swap the valve bodies so that the 4x4 trans can work on my ‘03




Second day it’s time to stab the new transmission




T-case shift assembly is in, so time to cut open the shifter plate to make room for it. Also lost a couple cup holders in the process but I knew that was gonna happen anyway



All wrapped up! Interior is good except for a shift boot (stealing my old Subaru shift boot since I replaced it a while back). Otherwise all I need now is to shorten my drive shaft 310mm to fit the transfer case. Also need a speed sensor since there is none for this trans (probably came out of a 4Runner)



But for now, she’s sitting pretty! New trans is in and ready to roll. Gotta top off my fluids and fix up my drive shaft and speedometer situation but otherwise we’re golden!

 

Hell yeah!

 

I'm currently looking for a shop to do my transmission work. Only part of the prep that's giving me trouble.

 

Luckily my company has a small shop and they let me use the space when inventory is low. My driveway sucks for this kinda work so I’m thankful I had a place to work on it

 

Got a lot done: with the new transmission in, I got a boot for the shifter (reused my Subaru’s old shifter boot), got my shortened driveshaft in, and got everything filled with fluid. I wanna do some test driving before it goes on the freeway, but I’m happy to see how it’s going, was even able to get it a few blocks down without any unholy noises coming from the transmission or transfer case


Also for the sharp eyes in the audience, you’ll see the driveshaft is out of phase in this image, so the U-joints are 90° off, but I noticed this and fixed it earlier today also



Still have to top off on my transmission fluid but otherwise I’m very pleased with how the truck’s doing! Next step is to figure out a speedometer situation since the donor transmission doesn’t have a vehicle speed sensor on the output shaft

 

Do you have the measurements on how much I need the front half shortened? I know a good machine shop and talked to them today about getting my hubs pressed out/in.

 

Driveshaft got shortened by 31.0cm. If you shorten it, the shop you take it to will re-tube it, basically replacing the entire midsection of the shaft

 

And we have the same driveshafts even though I have a double cab right? Edit: Most forum posts I've looked at and specs confirmed they are thanks.

 

Yeah the Xtra cab and Double cab driveshafts are the same. The single cab is different though iirc

 

Of the driveshaft? When I asked for what measurements, they said “just make where the center of the carrier bearing is” but this was a driveline shop so they know what they’re doing.

They’re also going to need to redo your front half entirely since it’s a kind of “bellowed/glares” design. The used fully cylindrical tubing.

 

Finally!! Looks good!

 

She runs! Everything’s good aside from not having a speedometer, but I’ll see if I can get one from the guy who sold me the transmission. Once that’s figured out I’ll be ready to save for my front diff, CV axles, and hubs/spindles

 

With the transmission all dialed in I’m gonna get back to working on my rear suspension to hopefully fix some shaking issues. Bought a Wheeler’s 2” AAL kit to see if that helps my axle wrap a little bit. If that leaves me too high in the back I can level it out with my front shocks, but I’ll get around to that once I see how I’m sitting

 

Once my conversions done I'm going to have to deal with the taco lean I got from my OME lift. And look into axle wrap too.

 

My truck doesn’t lean too bad, but it gets these nasty shakes on the highway above 65mph. After checking my U-Joints, replacing my shocks, re-balancing my tires, and replacing my center bearing, it’s the only thing I can think of now since my pinion angle is good when parked but I can rock the truck back and forth with the parking brake on and the springs sag a good bit

 

Shake? Or a vibe?

Check the front wheels for play. Bad LBJ can cause movement, inner/outer tie rods, steering rack/bushings

You have manual hubs so shouldn’t matter for front drive shaft. Bent rear axles possibly? Bent wheel?

Run the truck in front wheel drive with the rear drive shaft disconnected. Then you’ll know forsure if it’s rear drive shaft related at all or something else. Could be where the rear drive shaft goes into the t case


I’ve ran into about every issue with buddies rock rigs

 

It’s an all-out shake. Wouldn’t be on the front but I’ve checked and fixed nearly everything on the rear except my springs, which I noticed were sagging really bad

Also I don’t have my conversion done juuuuuust yet so running in FWD isn’t an option yet lol

 

But @snowboard704 I’ve got some good news, it WAS the springs and axle wrap. Installed my AAL kit today and did a test drive at 70mph. Almost no shaking to be found!



She’s sitting pretty stinkbug but I can adjust the front shocks so the springs are a bit higher up (gotta love bilsteins), so that should level things out a bit

 

That’s great news that the leafs fixed the issue! Once the conversion is done well have to wheel some trails around Flag sometime

 

Yea totally! Still won’t be done for a while since I gotta buy and install more parts (plus I’ll be busy with school), but I’d reckon she’ll be proper 4wd by next year!

Till then I’m gonna be leaving it at my parents’ house in San Diego since I’m taking my Subaru back with me to Flag