MJS's SAS'd 2003 Xtra cab

Alright, where do I start... I got to a point with my old truck (2010 DCSB) that I decided it was too nice to keep modding - especially since I didn't use it as my daily driver. I have a Colorado ZR2 for that (thanks VW for the cash...).

So I decided to look for something that was a) cheaper and b) further along the path to a trailered rock crawler. This is partly due to being uneasy rock crawling in a rig that I have to drive home. Thats where this truck came from:

Meet my new (to me) 2003 Tacoma SR5 Xtra cab:

As she came 11/2018


As she came 11/2018

Now before I start building/upgrading/repairing this rig...lets get a feel for the situation:

Suspension/Driveline Mods:

• SAS front with Dana 44 high-pinion, open diff
• Rear axle swapped to Dana 60, spooled
• Bilstein shocks
• Leafs of unknown specs front and rear
• Disk brakes all around, ABS delete

Wheels and Tires:

• Fake beadlock wheels (steel)
• Toyo Open Country M/T LT385/70R16

Engine

• TRD Supercharger
• Electric fan (manually switched only?)
• Dipstick cut-off mod?

Armor/Body

• Bolt-on sliders (partially bolted on)
• Cross-member delete / Trail Gear Rock Defense T-Case Crossmember
• Flatbed (custom)

Unknowns to discover:

• Gear ratio

I will try to keep this top post updated over time, will start with a thread below.

 

Let's get down to business!
These are the things that I am concerned with to get this rig where I need it/want it.

1) Needs a front bumper and winch - not sure if the custom member welded onto the frame is compatible with the typical 1st gen mounting points? Will need to do some research here and may possibly need something custom fabbed. Note that there are no recovery points currently.



2) Need rear recovery points added either to the flatbed (will require reinforcement) or add a heavy plate to the frame below. Some of the welding on the hitch is questionable as well, but it is so high it won't ever really be used anyways.


3) Two things here a) install ARB air locker that came with the truck in the front axle and b) needs new springs or swap out for a 3-link setup. Current springs are about 1-2" from the bumps.


4) Another two-for here a) move away from vulnerable factory tank and filler nozzle to a fuel cell and b) mount some kind of permanent CB antenna (current is just a magnet)


5) Electrical system in general, truck needs a full inspection to remove/legitimize previous wiring jobs. Specifically a couple below I would like to remedy are pictured a) tail lights will eventually short out due to back of back clearance inside bed tube. b) Old oxygen sensor is still hanging out and wiring is frayed...there has to be a better way to do this, like unplug it or something. I would assume the tune got rid of the need for it.


6) Sliders are kinda bolted on currently, need to at the very least finish these or weld them on. Or exo-cage...


7) Exhaust system is quite the amateur hour but could work for a while. T- is 90* and angles are hard, sizing is good though, certainly no real flow restriction. Also check out this sweet mount - I'm sure it wont tear itself off at all one day:


8) Other items

• Replace check engine light (bulb is pulled)
• Replace knock sensors and knock sensor harness to get more power out of the SC
• Automate the fan for AC/hot coolant to turn it on automatically
• Replace rear spool with an ARB
• Replace wheels with 1" less BS on them (can't fit on an 83" flatbed currently) and maybe legit beadlocks

Current Priority: (subject to change, work in smaller items from above)

1. Knock Sensors / CEL light?
2. Wiring issues - don't want to burn down the truck
3. Front ARB install (its sitting in my garage so it only costs me labor) - might need to decide if I want to adjust gearing here and order gears for both diffs and pull up the rear ARB to here...
4. Bumper/winch and rear recovery points
5. Wheels with less BS / beadlocks
6. Rear ARB install (need to buy)
7. Three-link suspension for front
8. Exo-cage / race seats

 

Looks like a good start!

 

I would just build a bumper out of tube off that front crossmember and use the tube as a recovery point. A winch plate and winch is also needed on there. Looks like a good start though, you are bypassing all the hard fab work!!

 

@MJS by rear spool are you refering to a mechanical LSD?

Sub'd

 

I’m in for this

 

Nahh like a serious spool or welded spider gears...I can tell you that it is basically undriveable on pavement currently so I might bump up the priority on throwing an ARB in the dana 60 as well. I'd like to have it in a condition where it is road capable and road legal for going between trails in the likes of Moab or Ouray.

spool example: https://eastcoastgearsupply.com/i-16015735-dana-60-spool-4-series-35-spline.html

 

Got down to work this past Sunday with a mission to replace the knock sensors with new OEM toyota sensors and wiring harness. Someone had already tried the tie the two together method so I got to reverse that as well. As with any project diving into the engine I forgot to order some of the needed parts...

Got the TRD supercharger off and cleaned up - bearings feel good on it


Eventually after much had wringing about taking the fuel injectors off, I finally took them off. Decided after a little research to keep the OEM ones and just get an injector seal kit, which should be in on Tuesday. I have since carefully masked, cleaned and removed the existing o-rings and grommets. They are ready for reinstall once the new seals are on.


After removing the injectors and a couple coolant lines, it was pretty easy to lift the manifold out. I used the long bolt from the supercharger to help lift it out without damaging the surfaces. You can see the new knock sensors and wire installed here. While the heads and gasket surfaces still look really dirty...trust me they were way worse. Probably about 1/4" of oily mud/sand on top of the intake manifold. I am pretty certain this truck did some time as a mud truck.


And here it is with the manifold reinstalled after being cleaned us as well.


Holding there until the injector seals come in, then can finish up. Also I cut the heater hose in frustration/error so I have to splice that

I also got my spline drive sockets in so I busted down the Dana 44 ARB to take a look (it also needed grit cleaned out of it anyways). Very clearly it needs the long cross-shaft so got that on order.

 

Just curious man, what did this cost you? I’m currently starting to feel the market for a rig I can wheel hard and daily for work. Would prefer something solid axle and Toyota. Like I love this truck. Any idea what to prepare for? $5k?

 

I felt ok paying $8k for this one, it has some good parts on it. The kbb on this truck unmodified was like $5000.

 

That’s not bad at all! If it had a bed, id be shooting you an offer more than likely. Time to keep my eyes peeled for another deal

 

Buy Joe's old sas T100 and swap in a 4.7L or SC'd 4.0

 

Bought a winch, bumper, and an ARB for the rear with some black Friday discounts...here we go!

Any suggestions on gear ratio? It has 4.10 allegedly (need to check it with the ole wheel turn test). I was thinking it needs 4.88 to be close to stock with these tires, and I was going to go a little further to 5.13

 

For sure 5.13s. However, be careful how much money you dump into that 44 up front. They can turn into a huge waste of money. There is a certain point that you should just get a dana 60. What bumper did you order?

 

I have 5.29s with 37s and a 3.4 and love it, my trucks driven to the trails (8+hrs one way usually). Lower the better!

 

Yeah I would probably swap that axle before conversion to a 3-link. Going go on and regear it and throw the rebuilt ARB in there for now.

Since mine has that section welded on right below the normal bumper mounting point, my options were pretty limited. It seems to have the bolt pattern for the trail gear one so will see if that fits, if not it goes back to 4wp and something custom has to be made.

 

Thanks, good input. I think I am limited by what the D44 can take ratio wise. Just curious what kinda RPMs do you run at 70mph?

 

I don't remember. I just know I can acclerate in 5th gear and pass with out downshifting and all that cool stuff!

 

Boom ordered 5.38 gears and master install kids from ECGS, both sets will go in on an ARB

 

Trail Toys is doing custom fab now.