Matthew's Jade Green 4x4 Conversion. (and other upgrades)

I thought I was being overkill custom making the 4HI and 4LO indicators.

And then I met @mjhenks

 

I'll take that as a complement.

 

Ground points under both left and right kick panels.

 

Thanks Jon. Are they traditional ground screws like what is found in the engine compartment or are we talking about tying into the harness?

 

Today I got to test out 4wd in the dirt. Nothing exciting. Just wanted to drive a little. No issues.

I made my transfer case switch harness.





Pretty happy with it. Cable is heat shrunk the entire length and then covered with mesh. Ends are double heat shrink, soldered crimps and silicon backed. Should be weather proof.

Made two of someone needs one.

Will not get to install for a few weeks but happy so far.

 

Nice! What’s up with the RTV, those connectors use little rubber boots crimped to the terminal to seal it.

 

The RTV gives me PTSD to trying to make my eBay VSS plug stop leaking. Took it apart. Put RTV allover everything. RTV around the plug hole. I've tried multiple different o-rings. Still leaks out of the electrical plug.

 

The plugs were not working with two wires in there. Could not get them into the back of the shell.

 

Been out of the country. Back now and finally got to install the transfer case harness i built up. Took me about 30 seconds to find out it was all wrong. Connectors were not right. Very frustrating.

There are two blue connectors and one white one. Back to square one. How do you go about identifying these connectors correctly?

Best image i have right now.

 

Thanks you @mechanicjon for the assist here. The connectors i needed are 90980-11156 and 90980-10923. What i was using was 90980-11250's. Basically the wring key.

Below is the connector list. You are looking for D3, D4 & D5.

https://www.tacomaworld.com/attachments/transfer-case-connectors-part-number-pdf.3373934/

Thank you.

 

Finally got around to installing the Tundra Brake upgrade. About 6 weeks ago i test fit everything and did some clearance work on the calipers. Time to go for it.

The parts.

Calipers from Napa.
Rotors, Pads & Shims from Toyota
Brake lines from 4Wheel parts


Brake lines front and rear. Fronts are Left/Right. Rear it alot easier if you drop your spare tire.



Installed.


What i learned. Make sure the brake fittings are threaded in proper before you put the wrench on it. It was hard to tell working from the back side and the bracket for the hard/soft hose is not the most accessible. Especially on the drivers side. After the "Doohhh!" moment and calling around the dealers i learned that i was out of luck for at least 5 days. So lets make our own.


Easy to do and there is alot of wiggle room. I used a 12" Japanese straight line from Auto Zone.

I also learned that it is ALOT easier to install the soft line into the hard line and then feed the hard line through the bracket.


So far so good. I do have a little rubbing under hard turns so i will remove a little more material. Otherwise i do notice they are a bit nosier but stop well.

 

Trying to catch up as alot has happened in the last 3 weeks.

Tundra brakes
- Work great. Stop great. I probably need to clear out a little more room on them as occasionally i hear a rub.
- My main issue right now is a serious case of the pulls. I have a different thread for that so i will not detail that here.
https://www.tacomaworld.com/threads/front-end-brake-conundrum-what-gives.615793/

Front End.
- OME 881's & Bastien 5110 installed. Set to zero.
- Pretty straight forward. Did not install the levelers. I ended up with a 1/2" lift without levelers. I am still about 1" too low so levelers will go back on eventually.



That is all for now.

 

If you decide to swap before I get around to swapping mine I'd be more than happy to help so I can do it to someone elses truck before mine LOL

 

You guys are funny. Honestly it was a bit daunting at first but there is so much info and so many guys who will help (albeit virtually) here. Plan and read alot. Then plan some more. It can be done step wise so you do not have your truck down. I would say the only specialty tools i could not do without were:

1. Hydraulic press. If you do not have this then you will have to hire out your spindle work.
2. Impact wrench with at least 2 feet of extension. Well you can get away without the impact but you do need the extensions and 1/2" is best.
3. Star driver set.

Anyways. The reason i made the thread was not only for me to get help but to help others too so go forth and convert...

 

Finally finished the transfer case switch harness and got it almost installed.


Plug into the three switches at the transfer case. Two on one side and one on the other. They are keyed so you can't get them wrong but then again all i am doing is tying the three switches into one so if any one is tripped my dash light will come on. No computer here.

I will zip tie them to the speed sensor harness that i had to extend for the conversion.


Many poke a hole in the shift boot to get the wires into the cab. I did not want to. There is a bump in the right side of the shifter plate so i routed the cable there. I know it gets a bit crushed but it is ok.


Route the harness straight back under the center console. I am going to tie into the harness on the right side above the glove box and find a suitable ground in that area.


The harness is fully sealed. Heat shrink the entire length. Silicon seal on the connectors and the entire thing overlaid with mesh for further protection. Way overkill but in case you did not notice yet that is how i roll. Next is to take the dash apart again and install the light in the dash pod.

I made three harness in case anyone needs one.

 

Nothing spectacular but did a light 10 mile trail twice this last week on the way to and back from Boy Scout Camp with no issues.

 

Took front end apart again today. I have been fighting the front end pull again and the truck is no longer safe to drive. See detailed thread here.

https://www.tacomaworld.com/threads/front-end-brake-conundrum-what-gives.615793/

Anyways. About 13 months ago the local Mountain Tire Goodyear replaced my LCA bushings and UCA assemblies. (MOOG) They also replaced two camber cam assemblies. Well lets just say if you want it done right...












All four bushings are being replaced again. One of them was totally shot and the rest suspect.

Using Whiteline W53377A's

https://www.whiteline.com.au/product_detail4.php?part_number=W53377A

I hope that solves my issue.

I also got myself a transmission cooler.




Going to mount it similar to the images on page 1 of this thread. (@zero4 thank you for the images of your mount. Very clean)

https://www.tacomaworld.com/threads/hayden-transmission-oil-cooler-install.108470/

Hope to have that installed in a few weeks.

 

My front end is back together and the pull is gone. It was the LCA bushings. Also added back my front levelers so my truck sits level now and looks very nice.


I had to get creative to get the 881's and 5100's installed with the 1" levelers. What i finally ended up doing is taking off the upper and lower ball joints. Leave the upper hanging by a few threads. Install the spring/strut assembly in the LCA. Stick a pry bar on top of the UCA into the spring and pry down until the lower ball joint sticks out enough thru the LCA to get the threads started. Then tighten everything up. Getto but it worked. I hope the front end work is now 100% done.

I also started:
- re-finishing the front head lights.
- Installing LED headlights.
- Installing the oil cooler.

What i have left planned other than finish the above is:
- Install the 4WD dash light.

What i am not going to tackle right now:
- Rear wheel bearings
- Rear brakes.

Will get more pictures up when i can.

 

Headlights finished. No image of how much light they now put out but i am very satisfied.

Starting point.


After 340 grit, 600 grit and 1500 grit wet/dry sanding.


After polishing with Meguiars "PlastX" and applying 3M sheet.




I also changed out the bulbs with a set of H4 Morimoto 2 Stroke 2.0 LED bulbs. These make a huge difference.


Next i have to adjust the head lights down a little so i do not blind other drivers.

Last update for today is my oil cooler is installed. I made some aluminum spacers and a bracket. Will plumb it next.

 

Time to test fit another "want". For sure not a "need".





Smittybilt 12K behind the front stock bumper. Following this thread.

https://www.tacomaworld.com/threads/mounting-a-winch-not-wench.100670/

It fits. I will have to fab up a mount and weld it to the Curt front hitch and trim the bumper "Tupperware" a bit.