MJS's SAS'd 2003 Xtra cab

Boom, repaired the hose and the truck started right up with no fuel or coolant leaks. Now to address some of the electrical issues.

First off, I can't even really connect this optima...the posts are too far away. Also it has no hold down.

 

Boom. Battery secondary cables extended with new 6ga wire and also got around to getting the running lights fixed. Rears were miswired (completely rewired those) fronts were burned out.




Also took the dash apart and moved the buned out CEL to the ABS light position and moved that bulb to the CEL spot...voila now can see if I have a code in and no more ABS light.


The horn still won't honk and that's the final thing it needs to pass a safety inspection to be road legal. I have a cheapo clock spring on order because I am pretty sure that's the cause.

 

Got the clock spring installed today and that did fix the horn!!! She can now pass a basic safety inspection. Also properly abandoned the after catalyst O2 sensor that was dangling.


Once she is registered in Blanco, next big project is dual ARBs and a regear

 

Badass work so far man

 

A friend and I pulled the D60 axles today, which luckily were 30 spline. Will need to press the bearings on the ARB unfortunately so a trip to the shop for that and the two pinion main bearings. Also rebuilt the D44 ARB with the new cross shaft that I ordered.

 

Nice man good bones and progress.

 

Just a little progress update...spent a while trying to get a case spreader for my D60... finally at least got most of it and made the last side. The guy packages this thing which weighs about 50lb in a thin cardboard box, so of course parts would fall out.

Anyways, done with the rear axle and heading up to the D44 in the front for an ARB and regear as well.

Here are the 5.38s and ARB installed and the final drive pattern (.008 BL)





Buttoned up!

 

In!!!!!!! This looks pretty sweet.

 

Sub a dub dub. Awesome truck and I love seeing the work you're putting in. Are you able to do any welding yourself? I would guess you're competent enough based on the rest of this thread.

 

Thanks! Unfortunately I have not invested the time to learn to weld. That said I have a friend that will weld for beer.

 

That's a good friend to have! As someone who's just starting to get decent at hobby welding, if you have any desire to try it, then I say go for it. It's a freaking blast and you'll be amazed at the small, misc doors you'll find opened like brackets and whatnot.

 

Finished electrical work today. Got the engine fan rewired with larger 12 gauge wire, installed the 6-gang relay box, and wired in the ARB compressor and solenoids.

And as a plus, no air leaks internal or external on the rear ARB install.

Before I hit the trails just need to install the 5.38s/ARB in the D44 and install the proportioning valve and new rear calipers in the brake system.

 

Front diff got done

Lucky I checked, there were already two holes in this diff that we're just wide open...drilled one out a bit and tapped both (one 1/4npt and one 1/8BSP)


The drilled bearing cap unfortunately is from another diff...but it should be OK...maybe. Specs are good - 0.005 BL and good pattern as shown below.

 

Got the bumper painted and winch installed! It's a smittybuilt but it will work till it breaks...Had to clock the gearbox about 72° off vertical to avoid trimming the grille. Mounted the relay box vertically as well to avoid trimming.


For now just going to strap down the spare, have to figure out something better later. Snuck in the fire extinguisher mount as well.



Going to take the rig on a shakedown run next weekend and if everything is good, already have Toyota Jamboree booked.

 

That wood floor in the bed is freaking nice.

 

Changed the engine oil for first time today - put back Mobil 1 syn High Mileage 5w30. This is mostly a note for myself...

Did and engine inspection and looks like all my work held up leak free so far

 

Bump

 

Alright let's catch up a bit. Here are som pics I forgot to post!

Camping on the trailer at Fall Run


Fall Run




At the raffle


Picking up some beer

 

Few more pics

 

Due to some changes (twins on the way) and some soul searching on my true off-road desires, I will be selling this rig in the near future. I have moved this truck forward in a pretty significant way, so lets recap how the truck stands today.


Road Legal Stuff

• Received successful inspection in Blanco County, TX (twice now). Was not previously registered or titled in texas (basically off-road only)
• Properly titled in Texas to me, easy to transfer properly now
• Restored functionality of horn, blinkers, tail lights, and e-brakes, simplified brake system tubing and added proportioning valve
  
• Added license plate holders (removable for off-roading) and plug-in license plate lights for the rear
• CEL light restored, ABS light muted (ABS has long ago been gutted from this rig)
• New windshield wipers

Engine

• Replaced knock sensors with OEM (real OEM, not fake OEM) sensors, new gaskets all around on injectors and intake manifold. No leaks noted since work completed.
• Only CEL is now 2nd O2 sensor (it is deleted - I would consider adding back the cat and this O2 sensor or getting a tune to get rid of this CEL, the computer is intended to use the 2nd O2 sensor to calibrate the primary (intact) wideband sensor)
• Oil and filter change with high-mileage synthetic; make sure to run the truck at least bi-monthly to full temps
• Added Ultragauge for reliable coolant temp and other engine variables monitoring

Electrical

• Replaced cooling fan wiring with appropriate automotive wiring and sheathing where appropriate. Previously fan wired with THHN wire to a toggle switch with various gauges (super sketchy).
• Replaced, audited all fuses (some incorrectly sized)
• Replaced airbag clock spring (fix for horn)
• Repaired tail light wiring connections - were wired incorrectly
• Removed old 2nd O2 sensor and abandoned wiring more appropriately (available for restoration if desired)
• New duralast gold battery (previous optima was toast)

Tires/Rims

• Purchased additional rim and full sized spare - strapped onto the flatbed
• Other four tires in good condition, almost full tread

Drivetrain

• Both differentials replaced - front - older Dana 44 ARB air locker rebuilt with new crosspin; rear - new Dana 60 ARB air locker
• Installed used ARB air locker compressor, tubing to both ARBs
• Installed ARB breather system to both diffs (ready for high water)
• During diff change, changed gear ratio to 5.38 front and rear from 4.10; this should roughly restore factory drive ratio (in terms of road speed) if my estimation is correct
• New seals on diffs during work
• Repacked bearings in front hubs, cleaned and repacked locking hubs

Brakes

• Rear calipers upgraded to El Dorado calipers (cable e-brake)
• Removed superfluous ABS tubing that was poorly abandoned in place - this had attracted attention during the first failed safety inspection that was attempted
• Added proportioning valve on rear brakes supply
• Fluid flushed as a part of this work

Other

• Cleaned interior with upholstery shampoo (needed it bad)
• Cleaned all plastic surfaces with armor all (also badly needed)
• New weathertech flexible floor mats
• Fire extinguisher mounted on rear flatbed
• Removed bro stickers from windows

Suspension

• No major changes here - did replace front springs, but practically ended up with the same results as previous springs. Would recommend 3-link and coilovers if you have the cash. Otherwise invest in some good bump stops
• The rear suspension is fine

Recovery

• Installed tube winch bumper in front to existing welded on mounting plate and factory tie-in points
• Installed Smittybuilt XRC 9500lb winch
• Installed Smittybuilt thimble

Key Stats Summary:

• 2003 Toyota Tacoma Extended Cab
• V6 with TRD Supercharger
• Odometer Mileage: need to verify exact number, its around 200k
• Solid axle swapped front and rear: Dana 44 high pinion in front and Dana 60 in rear. Bilstein shocks and leafs.
• Tires: Toyo Open Country M/T LT 385/70R16 (37s)(incl spare)
• ARB air lockers front and rear
• 5.38 gear ratio
• Approx ground clearance: 22" to bottom of T-case skid, higher elsewhere
• Custom flatbed
• Road legal in non-emissions testing areas (includes removable hitch receiver license plate holders)

Freebies with truck:

• Battery hold-down tray