Ugly Gold 4 door Hoor SAS-LS

2002 Pre-Runner W/lift kit, mud tires and a winch.

Toyota Dual Case assembly- Page 1
Toyota 2wd to 4wd tranny conversion- Page 3
Gm 14 bolt prep and regear- Page 2/7
Gm 14 bolt case shave- Page 6
3.4 engine pull- Page 8
Front Frame chop and notch- Page 9
Ford SD housing prep- Page 11,19
Engine bay paint- Page 12
Tundra oil pan setup on 3.4- Page 14
3.4 Solid motor mounts then scrapped motor - Page 16
LS motor/solid mounts in- Page 17
SD steering arms V1- Page 19
Methods arrive- Page 20
Toyota steering gear frame mount- Page 21

 

I chose to start on the rear because my 4wu kit is not ready but mainly to get in the groove.

UPDATE - JUMPED SHIP ON A KIT. SOLO MODE ON THIS ONE.

 

Nice!

 

Rear suspension-
-89-98 chevy 2500 leaf springs 3/1 pack. These springs have a 9/16 eye on both sides. The 99and up have a 9/16 and a 7/8 eye so you have to used guides. The barnes kit has these but its more stuff that can break and squeak so I went with simplicity and the 3/1 seems right for the weight of the bed. - $375 new from local spring co.

-I used the factory rear mount so i didn't have to grind it off. The offset shackles are for that purpose. If you cut it off and use the new mount you don't need offsets.

-ruff stuff 5/8 offset 6" shackles (shackle in pic are not offset. Learned that after) Need a drill press to drill all shackle holes bigger. $12.95 x 4 + $52

-barnes 4wd chevy 63 kit plus 2 anti wrap spring perches, 2 bent axle shock brackets. Didnt need the shackles so piece by piece may be cheaper. $296 shipped

- front mount moved 7.5" from original but with 40" tires I would do 6.5-7" if I was to do it over.

UPDATE- geez, looking back those welds are horrible even by my shitty standards. Those will be grinded and re welded.

 

Trail gear dual case adaptor (get a marlin mc09 if you can find one) TG is suspect. $823 shipped from poly performance. Get the transmission coupler from marlin. TG coupler is supposed to be shit. Not gonna use it to find out.

 

-1 x Competition Total Spline Input Gear - $239.00
SKU: MCTC-321C
-1 x Gear Drive Counter Shaft Bearing - $29.52
SKU: MCBE-133
-1 x Gear Drive Input Bearing - $25.52
SKU: MCBE-132
-1 x Input Pocket Bearing - $15.00
SKU: MCBE-2321
-1 x HD Transfer Case Rear Output Seal - $9.99
SKU: MCSE-423EC


-When you press the new bearings that you should buy from marlin also (input shaft and counter shaft bearings) DO NOT press this gear thing back (yellow arrow second pic) on like factory. You don't need.

 

Pics of the t cases.

-Top is the top shift (you want topshift t case for the new case) see marlin t case bible to know difference.
-bottom is the one that your 96-04 tacoma comes with. (j shift is the case without ADD or an actuator) good for sas. Half of tacomas and 4runners came with these. $200
-The pic with no arrow is the forward shift case. You don't want this. more money, more work.

 

Dang gif doesn't work. Anyway.... Nice!!

 

This is the new reduction/crawl box put together. Follow directions with dual adaptor kit and you will get this.

-if you buy a trail gear kit do this
- dont use 8mm dowels, just the bolts to join the adaptor and the 88-95 case.
- grind down some of the shift rod from the hi low rod (i think) you will know when you put the transmission adaptor on the crawl box. It literally hits when you shift. Grind that one down till it doesnt hit anymore.
-Drill out the holes where the new provided black studs go into the rear (t case that came with your truck) housing. I mean drill out the holes in the brand new trail gear case with a 3/8" bit if the case does not fit without binding. If it fits without binding you are lucky and dont drill. (bottom pic. The holes the studs go through)
-dry fit all the cases before siliconing.
-use trail gear gaskets at your own risk.
-marlin will not apply to any of this. Their product prob works without any bullshit but idk for sure.

 

Axles I chose

-front is a 2005 to 2009 ford f250 super duty - $400 junk yard
-rear is a 2002 gm 14 bolt off a chevy silverado. 99 and up i think is a ribbed housing and most have disc breaks. I wanted that. $600 junk yard (make sure to get an open diff with no posi!!!!)

-I only have the gears for the 14 bolt but below is the gears i chose. 5.39's.

$288 Yukon Gear & Axle (YG GM14T-538T) High Performance Ring & Pinion Gear Set for GM 14-Bolt Truck 10.5 Differential

Yukon Gear & Axle (YG GM14T-538T) High Performance Ring & Pinion Gear Set for GM 14-Bolt Truck 10.5 Differential
- I chose a standard bearing rebuild kit cause i got it on Amazon for cheap and yukon uses the same bearings.

$170 USA Standard Gear (ZK GM14T-C) Master Overhaul Kit for GM 14-Bolt Truck 10.5 Differential, Silver

USA Standard Gear (ZK GM14T-C) Master Overhaul Kit for GM 14-Bolt Truck 10.5 Differential, Silver
-I chose a yukon grizzly rear locker from amazon as well. You just need 98 and up for all the parts above.

$425 Yukon Gear & Axle (YGLGM14T-30) Grizzly Locker for GM 10.5" 14 bolt truck with 30 spline axles

Yukon Gear & Axle (YGLGM14T-30) Grizzly Locker for GM 10.5" 14 bolt truck with 30 spline axles
-The only thing that is important is your carrier. If your axle is a 4.10 down to 3.43 or whatever the lowest is you have a low carrier. If your axle came with 4.56 to 5.13 or whatever the highest is you need a high carrier kit but most are 3.73 or 4.10.

 

T case joined to crawl box

Twin shifters - https://frontrangeoffroadfab.com/twin-stick/
-you have to cut shift fork to clear trim stick arm. (Pic soon) (See page 5)
-you have to take that tic tac out. It is between the shift forks where the allen keys with springs and balls ride on the shift rods.


J-case diagram

 

Crossmember

I went with a front range off road dual case crossmember. $265- https://frontrangeoffroadfab.com/tacoma-and-4runner-t-case-crossmember/

-if you get this dont bother welding the mounts they give you because they prob wont work or only 1 will work. Get the case in there and jack it up and figure it out then. The ones I got are not big enough to span the width of the frame.

 

At least you're running mc 4.7... better choice over the tg. Make sure to run mc female coupler

 

I can’t buy one! Marlin doesn’t sell individual. If I call will they sell me one?

 

Yes, they sell that piece individually. Its not listed on their site but you can buy it over the phone. Left is MC vs TG right. The splines are cut better, cleaner, and have a tight fit vs TG. Less deflection. If you're running mc 4.7, I would run mc coupler and not the tg.

 

Yeah, I have heard a lot of bad things about the tg coupler. I’ll give Marlin a call.

 

Had some time to work tonight. Got my ass beat by completely seized e-brake pads. Used every tool I had on this POS junk yard axle.

UPDATE- WASTE OF FUCKING TIME. GET A NICE AXLE!

 

Plasma cutter my friend, get yourself one. Save yourself a headache.

Love my 375 and would not work on any rusty project without it.

 

Opened up the housing and started cleaning but ran out of time. Hoping to strip the axle and wire brush it friday. The housing is in better shape than I thought. Don't need to have it sand blasted.
tools needed - https://www.amazon.com/Carrier-Pini...prefix=yukon+bearing+press+tool,aps,58&sr=8-3

parts needed to fix broken shit -

$24 Dorman 924-743 Parking Brake Lever Kit Compatible with Select Models

https://www.amazon.com/gp/product/B00IWN4SHS?ie=UTF8

$58 Dorman 924-223 Rear Brake Dust Shield Compatible with Select Cadillac / Chevrolet / GMC Models

https://www.amazon.com/gp/product/B008J1OTGI?ie=UTF8

$33 ACDelco Professional 18K1618 Rear Parking Brake Hardware Kit

https://www.amazon.com/gp/product/B000EQQV6W?ie=UTF8

 

Shit! I have an esab. I didn't even think about breaking it out.. I thought it would be easier and it just got harder.