PreRunner 4x4 Conversion Journey Thread

You're probably going to want to mentally prepare to change those out for ABS or ASA. Looks like you got the contours right though!

 

Great Job. Reading this was a trip down memory lane. Glad i was able to passively help which of course is one reason to make a build thread. Really like your dash screen.

Have fun with it.

 

Haha man I haven't even gotten PETG dialed in on my MK4S yet, so I will die on the PLA hill until proven otherwise lol.

 

Thanks for all your help! It was an incredibly fun and rewarding project, kind of sad it's mostly over haha

 

Some mini updates, I received my 2 degree Tom Woods axle shims that will hopefully fix the slight vibration I'm getting at speed, presumably from the pinion angle. For anyone's reference, it's currently at roughly 4 degrees when comparing the rear diff flange face to the rear section of the driveshaft, so we will see how much the 2 degree shim affects it.

In some more annoying news, I currently have a small leak of ATF where the transfer case mates with the trans, so presumably some issue with the output seal on the trans. I can't even describe how much it pisses me off given seals were something I was particularly diligent about during this process. My only thought is I may have either damaged or dislodged it a bit when trying to install the transfer case shaft. It's just a drop (for now), so I'm going to ignore it as long as I can as replacing that again will be a huge PITA. I also noticed a potential leak at my driver side front diff CV seal, which really doesn't make sense to me as there should have been no contact that would've dislodged it, and both of these seals were brand new OEM. I suppose that's just the way she goes..

other than that, everything is going swimmingly. Trans has been driving great, wheel bearings and hubs are smooth. Still searching for some light off roading to really test it out!

 

Oh also for any of those with 3D printers, here is the file for the ScanGauge mount I made! It works quite well.

 

I had that same leak on the transfer case when i did my swap. I replaced the seals with OEM ones. I left it as is and kept an eye on it but it never really leaked much to be honest. Nothing on the floor and the fluid level stayed where it should. Im not sure what was going on there.

As for the front diff leak. When you installed the new seals did you install them all the way in? I believe those seals are suppose to be installed flushed. Kind of hard to explain but Ive seen many install these wrong and they get a leak.

 

Good to know you had the same leak and it didn't end up being an issue. Same here that it's barely a drop, and hasn't affected my fluid level as I've been checking it regularly. For the front diff though, I'm quite certain I seated it flush (see pic)! The only thing I'm now remembering is when I was fussing with trying to remove the intermediate shaft from the A.D.D. system on that side, I was levering a pry bar, and there were a few small nicks as a result. I do remember being aware of this though and noting that none of the nicks were in the seal area but rather on the outer edge and I even sanded most of them down a bit to smooth it out. I'll have to take a closer look though as it was kind of difficult to tell exactly where the drip was coming from. Luckily with the manual hubs the CVs are rarely spinning, so it's not a constant leak for now.

 

Yea thats the good thing that those cvs are not rotating when unlocked. Thats one of the great things about having manual lock hubs. If you do see it leaking when in use then maybe it wouldnt hurt to just replace it with a new OEM seal.....again lol although replacing it on the truck will be much more challenging.

 

Totally, it was a great luxury doing the seals for everything off the truck lol. But hey at least I have every single seal part # ready to go!

 

from the looks of that picture you posted of the seal the seal seems to be placed all the way in. Maybe its just the angle of the picture.
check out the video below from timmy the tool man. Skip to 5:35
Front Differential Axle Shaft Oil Seal Replacement