2003 4Runner Limited 4wd V8 FJ tcased overlanding rockcrawling do-it-all build

Finally got my VSC lights to stay off. Don't know why I didn't think of it before but I had to do a Zero Point Calibration. Duh.

 

???

 

VSC = Vehicle Stability Control. Anti-skid basically. They had been on since the stock tcase issues I had earlier and I finally got them turned off.

 

So I've given up on getting anything from RockSolidToys. I've tried many times, basically weekly, to get a status update on my order with them and have gotten nothing but excuses and empty promises to call me back with updates. Nothing has panned out. I've called 3 or 4 times over the last 2 days, even calling from a different number, left 2 voice mails and haven't heard anything. So this morning I called my credit card company and opened a dispute and am having the charges removed/refunded.

Ordered a twin stick kit from Front Range Offroad, a new V8 oil pan from McGeorge Toyota and have a front diff from an FJ arriving tomorrow from the same wrecker that I got the FJ tcase from. Once I have the front diff, I can start figuring out the wiring to activate the ADD from a switch in the cab.

 

Shitty, that seems to be par for the course from them.

 

Yeah, it's a bummer. I was hoping to make it easy on myself by getting all the pre-made shit from them.

On the positive side, I've got everything on order again, already have a tracking number from Front Range for the twin sticks and should be able to pick up the front diff today after work. And, so far, everything has come out to be about $500 cheaper than what RST was charging. That alone just about pays for both driveshafts being rebuilt.

 

That a plus and what I was trying to tell you earlier when you were sourcing parts, they charge a shit ton, for something that never gets delivered . . . Total BS.

 

Yeah. Well live and learn I guess. At least my credit card company has reversed the charges for me already.

 

I has front diff now, From a 2010 Tacoma with 148k on it. 3.73 gearing to match the rear in the 4runner.

 

Nice, while you have it on the bench I would suggest pulling the ADD motor apart and cleaning, soldering and resealing it.

https://www.tacomaworld.com/threads/how-to-trouble-shoot-4x4-actuator.263525/

 

Not a bad idea. I might just end up leaving the full-time front diff in for a little while too. I have a Moab trip mid-October and am not sure I'll have time to swap everything between now and then. Work and money, sucks.

 

So this has made up my mind to stick with the full-time 4wd front axle:

Right now, the plan is to do the tcase swap next weekend since I have a 3 day weekend. This weekend is unfortunately a regular 2 day and the driveshaft shop isn't open Sat/Sun. Probably leave the J-shift if there is room for the shifter with the console. We'll see.

I'll use the ADD diff I just got as a spare for regearing and front locker when the time comes and swap the full time axle tube onto it.

 

Fabbed up a cradle to help with the tcase swap. Looks like it should fit the stock tcase in the 4runner right now too. Used to old front diff drain plug from the 4R to help keep things less tippy. The threads are the same as what's on the HF Pittsburgh floor jack so I welded an SAE impact socket to it to make things easier/better.

 

Started work on a storage solution for the cargo area today.

 

Added some more L-brackets to get the sides straight and attach everything securely to the base board, which is bolted down in the factory tie down spots.



Also added backs to each compartment/soon-to-be-drawer areas, which in turn created new storage locations.

 

These pictures are sweet, thanks for sharing. I always enjoy looking at the cutaways of the inside.

Also neat that the front diff drain theads fit the HF floor jack, never would have though of that. I'll keep this tip stored in my brain for future use.

 

Started the tcase swap tonight. Took about 2 hours or so to pull the old tcase and temporarily mount the new tcase. That includes lifting the truck, pulling the driveshafts, dropping the old case, swapping trans mounts, mount the FJ case with 4 bolts and measure for the new driveshaft lengths. Stopping to take some pics too. Drop the driveshafts off tomorrow morning, first thing, hopefully get them back same day or maybe just the rear would be awesome too. Then home to drop the FJ case, remove interior parts and start cutting the trans tunnel for the new shifter to poke up thru.

I did receive the twin sticks from Front Range today but I'm going to hold off on those for now until I have the FJ case permanently mounted and am driving the 4Runner with it.

Driveshafts out. Front gets shortened by about 1 1/4", rear gets lengthened by about 1 3/8". Both are getting fully rebuilt as well since I have no idea if it was ever done and there are probably 291,500 miles on them like the rest of the truck.



Stock POS electronic tcase out. The cradle I fabbed last weekend worked perfectly, made removing this one and installing the new one very easy.



Crappy shot of the back of the tranny with the original trans mount in place. It's collapsed but not broken. Going to save it and see if I can fab up a stronger mount later on.





New trans mount in.



And FJ tcase temporarily installed to get driveshaft measurements and mark for where to cut the trans tunnel.



Lastly, the twin sticks from Front Range. Very nice piece here.

 

Driveshafts are dropped off.

Bad news is that he basically can't use much from them since the way they are made prevents him from being able to re-tube them. I forget the welding process but it's a no-go for cutting off on the lathe he said. So, he basically has to build me new shafts now. He's ordering the parts today but won't have them until Tuesday probably and has a day or 2 turn around to build them. So I'm looking at end of next week to get the driveshafts back now.

 

How well do you trust this guy ol? I retubed mine and it is pretty common.

 

Did you just have someone balance them after you retubed then, James? Did you bump up the wall thickness or anything?