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TomTom's '03 TRD Xtra Cab (SOLD!)

Discussion in '1st Gen. Builds (1995-2004)' started by tomtom, Jan 23, 2013.

  1. May 18, 2014 at 11:11 PM
    #701
    tomtom

    tomtom [OP] Well-Known Member

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    Got half way through installing a new flywheel today.

    pile 'o TGP to be installed:
    DSC_0025_zps00976c22_a92c180b60c544801e393cbea61ca3e80454117d.jpg

    The start:
    DSC_0026_zps22d84afa_9ec4856c63006d6b521b330eef66afe1762078e7.jpg
    Oh, yeah, some new toys to help me with the work this week. A shop press:
    DSC_0027_zps33042d65_7714eb9a03da4729f10ff1c3ce7782dfe3072392.jpg

    A transmission jack that helped immensely:
    DSC_0028_zps40ee21e5_f2ea29b88ca05f660f616c1f1e5753f5be2b9198.jpg

    Pulled:
    DSC_0030_zps90589e96_9d42ce55c2f78491425d7addb5d76cd1a12eaedb.jpg

    Marlin Crawler clutch kit. At least the shop installed that with no hiccups...
    DSC_0031_zps7da4662f_a30863e007151d6a99d1bf31323f321ee9ae0605.jpg
    The old flywheel with less than 20k miles on it. You can see the chunking created by the starter not inserting correctly.
    DSC_0037_zpsb0a6f0d4_0873aaa178d61028d907242ab6b076d5ad2744c4.jpg
    The TGP starter teeth with a nice bevel on them:
    DSC_0036_zpsde586256_71021dd210a3e697310667ef74b413fb043cc705.jpg

    The old flywheel with rough machining and a flat face:
    DSC_0038_zpsaade8b2e_4263d02fcbd3dbf47674677fc716ffda4135a7c4.jpg

    The mounting face for new flywheel. Nice machining with a good bevel for helping install and removal:
    DSC_0035_zpsb02ceff4_cc0b9afb0cacae6fc84e9a7e1d3c1af6f5e25688.jpg

    Material removal to balance the TGP flywheel:
    DSC_0041_zpse62780ff_16556734067f1c12cf220ddcf74b7fee67e81497.jpg
    Spent some time laying everything out. So much to be done. Starting to lower expectations on what will get done this week:
    DSC_0046_zps90ecf16d_141d3ad234cecc7a4412ede8cab9893ac2115039.jpg
    Organized the tools:
    DSC_0050_zps27b07bbf_dbc3418168e6a28fb78ac771404c3450f4a4e672.jpg

    The transmission waiting to take off the transfer case:
    DSC_0047_zps187be5f5_730dc545f67ebc10672e923b62710d76f9263557.jpg
    The transfer case taken off:
    DSC_0051_zps89f0c369_eee3a6629733dc8c3a23214124b884f65fa6ce66.jpg
    Gear oil was in the adapter housing which means the seal needs to be replaced.
    DSC_0052_zpsb590b204_c8d98746a3d0558f36a56c21c89d3b2a75865177.jpg

    Hoping to get it all back together tomorrow. The winch will be the next project this week.
     
  2. May 18, 2014 at 11:14 PM
    #702
    PcBuilder14

    PcBuilder14 Well-Known Member

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    Dang! Can't wait to have a second vehicle so I can take my time and do work at my leisure haha
     
  3. May 18, 2014 at 11:18 PM
    #703
    tomtom

    tomtom [OP] Well-Known Member

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    If I were hard up for transportation, I'd just get a rental. Much cheaper in the long run. After getting the transmission back in, most of the pressure will be off. All the other projects are non-immobilizing.

    I'm really a Toyota fan after doing the flywheel. My XJ was such a PITA.
     
  4. May 18, 2014 at 11:20 PM
    #704
    PcBuilder14

    PcBuilder14 Well-Known Member

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    20 year old renting a car, yeah right haha
     
  5. May 18, 2014 at 11:27 PM
    #705
    tomtom

    tomtom [OP] Well-Known Member

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    Don't you get a "Too Young To Drink" discount? :eek: :D
     
  6. May 18, 2014 at 11:28 PM
    #706
    tomtom

    tomtom [OP] Well-Known Member

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    I love it. Pedal pressure is better than stock. Seems to hold fine. JLee just got an LCE kit that he speaks highly of. Has me thinking about it for the next clutch job.
     
  7. May 18, 2014 at 11:33 PM
    #707
    PcBuilder14

    PcBuilder14 Well-Known Member

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    Just over 5 more months... 5 more! Haha old man :p

    Jealous of your attention to maintenance detail...
     
  8. May 18, 2014 at 11:40 PM
    #708
    tomtom

    tomtom [OP] Well-Known Member

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    IMO, one of those things you have to experience once in your life. It does go much easier with the proper tools. It is doable with a regular floor jack but need to pay much more attention to balancing it properly.

    Damn straight! Now no hot dogging in the water!

    It is a gift and a curse. ;)

    BTW, Brent. Those shots are all taken with the new Nikon.
     
  9. May 18, 2014 at 11:42 PM
    #709
    PcBuilder14

    PcBuilder14 Well-Known Member

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    :rofl:

    How do you like it so far?
     
  10. May 18, 2014 at 11:47 PM
    #710
    tomtom

    tomtom [OP] Well-Known Member

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    I like it. I just need to make time to sit down and learn how to use it. Does really well with natural and low light shots on automatic. Looking into getting some different lenses.
     
  11. May 19, 2014 at 5:52 PM
    #711
    tomtom

    tomtom [OP] Well-Known Member

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    The new flywheel installed:

    DSC_0054_zpsbf38386e_e85184e33df4ce971d67f347296921bb7ad0814d.jpg
    Clutch installed. Look closely and you can see the alignment tool:
    DSC_0055_zps163c8492_d1e291eb780f022fb13e48bd390a2f08d6fbc027.jpg

    Pressing in a new oil seal for the transmission output:
    DSC_0057_zps6666600a_bdcea51c7b76afecdfabf799ffe6b61898d01d86.jpg

    Done pressing:
    DSC_0059_zps5e277003_2b00fde663a7826b49c32ab78bba84022afd3b5b.jpg

    Transmission back up and in:
    DSC_0060_zpsa782297b_7f77f0a3ef392b945b20ea730c70b4352a1be57a.jpg

    Have a bunch of little stuff to do like the starter, cat, propellors and fluid fill. Then test drive time.
     
  12. May 20, 2014 at 9:48 PM
    #712
    tomtom

    tomtom [OP] Well-Known Member

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    Finally test drove the truck today. Everything works fine. No bad starter grinding yet so I'm counting it fixed.

    In prep for tearing out the rear end, painting the axle and upgrading the suspension some more, some stuff came from Wheeler's today.

    I love open the box and seeing the candies. Makes my day doubly better:
    DSC_0063_zpsd33ab527_8cd4cfe2099cdfd6200931437573f066ae66e025.jpg

    The other goodies in the box:
    DSC_0068_zpsc39e911f_c573bbcc4b9293c74f5deae10a807d6c9e6dd3ff.jpg
     
  13. May 22, 2014 at 12:22 AM
    #713
    tomtom

    tomtom [OP] Well-Known Member

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    Mod week continued on today with the install of a BamaToy Stage II electrical upgrade.

    Heavy duty alternator:
    DSC_0069_zps34439558_48a7d5b8f6da9ba67c1d0110ba53030a5122278e.jpg

    DSC_0073_zps2ea88b45_bd5c6d218eacb77bfab55b375c9b01ea17a933ec.jpg

    Battery terminals w/ new starter cable:
    DSC_0076_zps5cee0655_08494493883a81596aa80345cb36569b413b3c3f.jpg

    Getting the Elite altered for the control box:
    DSC_0077_zpsd338a4e5_e028b8ebbade2fb5f6cb9049a790745a3a9ec87f.jpg

    DSC_0079_zps8670413a_0434da1eddb1b3c415105ed2052f7c9b9e19034f.jpg

    SGT Taco signing his work, like the artist he is:
    DSC_0082_zpsb76ec2ba_899624edd93b6ef28d0e27ef2f38d26e89a10fd3.jpg

    Getting ready to spool the line:
    DSC_0083_zpsebb06804_994d00aa3322c39c44aa45d7c2fde4dd63f76bc4.jpg

    All hooked up:
    DSC_0088_zps359efd55_e5df495c0cd2c8fa16d8c92e144323d69a2bbb10.jpg
    All buttoned up:
    DSC_0090_zpsc5150bb9_acf103716b45a393c1de2e87bb489ce8d69661c0.jpg
     
  14. May 22, 2014 at 12:33 AM
    #714
    ffirg

    ffirg Well-Known Member

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    Looks awesome!

    Question, did you relocate your blinkers to your corner lights? Or are the little amber ones your turns? And this may be dumb, but did you drill holes for mounting your lights? I got my bumper finally and need to drill my light holes before getting it powdercoated. I just don't know if it's that easy with a corded drill or not...
     
  15. May 22, 2014 at 12:51 AM
    #715
    tomtom

    tomtom [OP] Well-Known Member

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    The little amber lights on the bumper are the blinkers. I asked Tim to drill them for me. 3/4" I think. A corded drill should do fine. Find the right RPM and use a bit of oil. I don't know if you have any scrap to practice on but would be worth finding.

    I have the parts for the blinker relocation. Getting to it this weekend. Wish I had taken the time to do the blinker relocation before ordering the bumper so I don't have the 3/4" holes in it. Will be filling the blinker holes with 3/4" black nylon inserts once I move them.
     
  16. May 22, 2014 at 1:14 AM
    #716
    ffirg

    ffirg Well-Known Member

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    Hmm. You could also use your current turns as marker lights :notsure:

    I think the same lights were included with my bumper but no holes were cut. I'm planning on using the rigid A series lights I bought months ago. Just need to figure out how to wire them.

    Although I also bought two new corner lights to do the relocation as well haha. I think until I figure it out I'll just zip tie my stock turn signals on the bumper.
     
  17. May 22, 2014 at 9:31 AM
    #717
    w00dy

    w00dy Hey Now!

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    BAMF kick out sliders, SkidRow skids,Pro Comp 7069, Kelly Safari TSR 285's, Elite front bumpa, OME 883 & Dakars w/ D6XL AAL, Nitro sport shocks, Eddie209 Soft topper, Satoshi, k&n fipk, Clarion vx400, Ultra Gauge, Debadgination mod
    Great job! I do envy your attention to detail.
     
  18. May 22, 2014 at 11:19 PM
    #718
    tomtom

    tomtom [OP] Well-Known Member

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    It is a blessing and a curse. Most especially a curse right now. Started in on my version of the blinker relocation.

    DSC_0092_zps17ec3b18_991ec4ce46d0017e517a211529518613fc065cd4.jpg


    Cut up the donor blinkers for the light mounts:
    DSC_0093_zps60268acb_e2f515b9a6de5ad21db15826a0e9f31fa04710d1.jpg

    Cut the corner lights to fit. A massive hack job that I'll have to make up for with a metric shit tonne of epoxy.

    DSC_0094_zps11a788ee_f8ff78fbc7c06b74754412768a7cbf276c67037a.jpg

    DSC_0095_zps5dc9b643_fb4cdb47a2a3218ed21fd28bec5de2facbfb7faa.jpg

    Ready for the epoxy:
    DSC_0098_zps2a865721_a34a20361516f4ecc542a95dc9ec7595d8d15527.jpg

    If I had to do it over again (which I might) I'd set these up in a drill press and use the appropriate sized hole saw. Probably going to take me several applications of epoxy and sanding to get the gaps filled in nicely.

    This went better in my head. Figured I'd have a nice 2 filament bulb handle both the blinker and parking light instead of 2 separate bulbs. Not sure why but Toyota put 2 filament bulbs with a 3 lead connector in the bumpers for the blinkers. They just left one of the leads out.
     
  19. May 23, 2014 at 7:38 PM
    #719
    tomtom

    tomtom [OP] Well-Known Member

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    The blinkers are finished with much help from SGT Taco. One of the big pieces of advice he had was to skip the epoxy and use plastic welder. It mixed up thicker which made filling the gaps so much easier.

    DSC_0101_zps0fa54f90_d0e92f7a231a5489b340399a5bea7546e4751a78.jpg

    Trimming the sheet metal to make room:
    DSC_0102_zps88f9da4c_bd3c4cf2fe70b5ebca3fe0d0981f0befc613de03.jpg

    Soldering in the 3 lead harness:
    DSC_0110_zpse910933f_2235e53280ed221a8ef222c57aad68f545ca6ed3.jpg
    Hooking up the lightbulb to test:
    DSC_0111_zpsf046fa85_91993da2667d53a0bc466cd2e6ce0b4ffd58d66b.jpg

    Parking lights are on:
    DSC_0122_zps6204f27a_d46dc27cab51e0b1a57328888866299acaf33711.jpg

    And the blinkers:
    th_DSC_0123_zps17df6498_5ab1fc73d8d1e9f0fddab9eae4d6f300af41ee6a.jpg
     
    Last edited: May 23, 2014
  20. May 23, 2014 at 8:15 PM
    #720
    Madjik_Man

    Madjik_Man The Rembrandt of Rattle Can

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    So wait.... your parking lights act as your blinkers too?

    I'm confused (surprise, surprise).
     

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