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Vancity4x 1ton SAS Crawler Build

Discussion in '2nd Gen. Builds (2005-2015)' started by VanCity4x, Jul 6, 2013.

  1. Jul 6, 2013 at 9:33 PM
    #1
    VanCity4x

    VanCity4x [OP] Straight out of welds

    Joined:
    Aug 1, 2011
    Member:
    #60970
    Messages:
    1,393
    Gender:
    Male
    First Name:
    DJ
    BC
    Vehicle:
    05 Prerunner
    Hover truck
    2005 Prerunner, converted to IFS 4wd 2013, now running 1 Ton axles and 39's. Front SAS in progress

    Here's how she currently sits,


    [​IMG]



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    Mods

    Drivetrain:
    04 Ford Hp D60 Front
    -Ballistic cover
    -TMR Histeer Arms
    -35sp units/stubs
    -Warn hubs
    FF 14 Bolt Rear
    -Ballistic shave
    -Eldorado custom disk setup
    Front/Rear ARB lockers
    5.13 Yukon gears
    FJ Crusier Transfer case Front Range twin sticks
    Spicer built driveshaft
    Full breather Relocate
    Intake Relocate


    Kicks:
    39 13.5r17 BFG Krawlers

    Armor:
    Custom Front/rear tube bumpers

    Suspension:
    3 link front
    14" Radflo coilovers


    Chevy 63's rear
    14" Bilsteins custom mounts
    Ballistic Frenched hanger

    1’’ 4crawler Body Lift

    Offroad Recovery/Camping Gear
    Engo 10k winch
    HiLift 60"
    ARB CKMA12
    Tepui RTT on custom rack
    Trasharoo


    Exterior:
    Trailer products Fiberglass
    HomerTaco Satoshi Grill
    Rubber bed mat
    Kobalt tool box –Line-x coated


    Lighting

    Interior:
    Wet Okole covers
    Weather techs
    Cluster/Int LED Swap
    Fat Mat Sound Deadnd
    Scanguage
    RAM IPAD mount


    Audio/Coms:
    Kenwood ddx370 Head
    Alpine sps-600 series front/rear speakers
    Alpine V60 5channel amp
    JL 10'' sub w/custom box
    Cobra 18 cb radio w/ 4' Firestick
    2 Baofeng 5W VHF Radios
    Gamin Glo w/ BC Backroad maps on Ipad
     
    Last edited: Aug 16, 2015
  2. Jul 6, 2013 at 9:33 PM
    #2
    VanCity4x

    VanCity4x [OP] Straight out of welds

    Joined:
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    #60970
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    Gender:
    Male
    First Name:
    DJ
    BC
    Vehicle:
    05 Prerunner
    Hover truck
    Details of swap as outlined by the mastermind - http://www.rocksolidtoys.com/forum/showthread.php?t=396

    So to make a conversion of a 2nd gen prerunner possible will need to find all the parts,

    A750F 4x4 Transmission
    VF2A FJ Crusier (Automatic) Transfer Case
    Tacoma Front Diff w/ mounting hardware
    CV axels
    4x4 hubs/bearings
    CV nut/seals
    Front drive shaft
    ADD Harness - replaces ecu
    Custom tranny crossmember
    Modified rear drive shaft
    modified y-pipe exhaust
    +large assortment of mounting bolts, seals and misc parts


    The swap for me was around $3500 in parts not including the ARB or gears. If pieced together properly it can be done for cheaper. Most of my ability and knowledge came from a lot of research and the factory service manual which details all the parts on the truck.


    Heres how I did the swap

    New Tranny and TCase

    [​IMG]


    First off I took out the tranny. The connectors, fluid lines, shifter leaver came off then took out the starter to access the TC to Flexplate bolts. Then unbolted the bellhousing from the engine to pull the tranny out.

    [​IMG]


    Installed the new Transmission then cut the hole and sent my FJ Tcase home

    [​IMG]


    Have Twinsticks used for selecting the drive, left of for high, neutral and low and right for 2wd and 4wd. This also lets me utilize 2low for certain situations.


    [​IMG]


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    The prerunner frame is different then the 4x4 so a custom crossmember is needed. The measurements were not the easiest to get. I used 1x3 steel tube, cut the ends off a 4x4 crossmember and welded them to the new. Then cut out the center section and added them mount. [​IMG]

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    The IFS stuff is pretty simple, front diff bolts to factory holes, no crawl box meant factory front drive shaft would fit. Gusseted the spindles, through in the cv's and hubs with seals. Wired up the ADD Harness, works great. Allows the front diff to function without the use of the ecu. Before switching into 4wd the switch gets turned on activating the front diff, then the tcase can be shifted into 4.

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    At the same time as the swap I had my front and rear diff regeared to 4.56 and front locker installed. [​IMG]

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    For the rear drive shaft instead of buying a 4x4 shaft I was able to get my prerunner shaft cut down and a yoke and slip joint added. Cut the cost down rather than buying a new shaft and having to change the carrier bearing position, they are different on 4x4 frames.

    [​IMG]

    The last thing I got done was getting the exhaust relocated as It doesn't fit around the new tcase. You can see it in the bottom of the picture here, it is in the stock location now. I got it done by a shop. I will def be redoing it soon as it already has rock scars on it. [​IMG]

    [​IMG]
     
    Last edited: Feb 3, 2014
  3. Jul 6, 2013 at 9:33 PM
    #3
    VanCity4x

    VanCity4x [OP] Straight out of welds

    Joined:
    Aug 1, 2011
    Member:
    #60970
    Messages:
    1,393
    Gender:
    Male
    First Name:
    DJ
    BC
    Vehicle:
    05 Prerunner
    Hover truck
    Intake Relocate


    [​IMG]


    Tires - make big rocks look small :cool:


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    Fender chop


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    IFS


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    OMD style Leaf pack f150 springs


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    Shackle flip


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    Crusin -Beefy as Fuck- Sliders


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    ARB


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    Chains


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    Interior


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    Audio


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    Coms


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    Electrical


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    Early days


    Before Conversion


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    Click for full-size image (1024 x 762)
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    Click for full-size image (1024 x 761)
    [​IMG]


    Stockers


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    First lift, good memories


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    Offroadn 2wd


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    Last edited: Feb 3, 2014
  4. Jul 7, 2013 at 12:05 AM
    #4
    Stew Fidaso

    Stew Fidaso Member

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    #105187
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    Male
    I am very sorry to ask, how much work and money to convert to 4X4? I also have a pre runner. Thanks!
     
  5. Jul 7, 2013 at 12:07 AM
    #5
    somethinboutayota

    somethinboutayota Dorthy left Kansas for a reason

    Joined:
    Apr 2, 2013
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    #101146
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    4,299
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    First Name:
    Parker
    Dodge City, Kansas
    Vehicle:
    Go to get alignment- replace whole front end
    Debadged and painted, plasti-dip bumper , Sock monkey decals, tool box, K&N cold air intake, flag holder/fishing pole holder, Satoshi, magnaflow 40 series, spidertrax wheel spacers, map lights, led reverse lights, led dash assembly lights, roof top LED bar
    Awesome job with the truck so far and that's awesome you converted it
     
  6. Jul 9, 2013 at 4:46 PM
    #6
    bunxbun

    bunxbun Well-Known Member

    Joined:
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    First Name:
    Bunnath
    Santa Ana, Ca
    Plasti-dip emblems, Anytime Foglight, Wicked Flow muffler, 35w 6000k HID
    id love to know as well...:D
     
  7. Jul 9, 2013 at 10:14 PM
    #7
    VanCity4x

    VanCity4x [OP] Straight out of welds

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    DJ
    BC
    Vehicle:
    05 Prerunner
    Hover truck
    As I added above it would cost at least 3k in parts. Most the parts I was able to get for ridiculous prices from a friend with a wrecking yard. Regear and lockers was at least 2200, then suspension, wheels, tools ect. Not Cheap.

    Better pics and more details to come.
     
  8. Jul 10, 2013 at 2:49 PM
    #8
    bunxbun

    bunxbun Well-Known Member

    Joined:
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    114
    Gender:
    Male
    First Name:
    Bunnath
    Santa Ana, Ca
    Plasti-dip emblems, Anytime Foglight, Wicked Flow muffler, 35w 6000k HID
    nice, i might do this years down the road :D
     
  9. Jul 10, 2013 at 2:52 PM
    #9
    Khaos

    Khaos Well-Known Member

    Joined:
    Feb 4, 2008
    Member:
    #4570
    Messages:
    6,506
    Gender:
    Male
    First Name:
    Bryant
    Tallahassee FL
    Vehicle:
    2005 Prerunner TRD Off Road
    265/75/16 BFG A/T, 18" Magnaflow, K&N Intake Filter, Ultra-Gauge, Kobalt Toolbox, Metal Tail Light Guards, Cobra 19 and 4ft fiberglass antenna, Plasti dipped Badges/lower valance/rear bumper/grill/bullbar/ac controls, black DIN kit, JVC KD-X40, Wet Suit Seat Covers
    I need to 4x4 convert. I'm too attached to my truck to trade it in. Plus it's already paid off...
     
  10. Jul 10, 2013 at 11:14 PM
    #10
    Stew Fidaso

    Stew Fidaso Member

    Joined:
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    Hello. Thank you very much for your response. I wish I have your skills. Man, your truck is awesome!!
     
  11. Jul 12, 2013 at 6:45 AM
    #11
    Toy Yoda

    Toy Yoda Go Pro Junkie

    Joined:
    Apr 12, 2011
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    #54800
    Messages:
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    First Name:
    Garrett
    Red Stick
    Vehicle:
    06 DCLB
    Sdidertraxx, ARB deluxe winch bumper, Warn M8000, Westin Tailight guards, 5100's, OME 886's, OME N182's, 2" block, 1.5" aal, Pioneer 4300dvd, stickers out the butt, misc crap
    how sketchy was it welding up that new cross member? i might be getting an FJ T case for $150...and now that i've found the ADD system to trick the actuator i'd actually be tempted to try to convert. the only thing that scares me is rewelding a new cross member like that
     
  12. Aug 3, 2013 at 8:40 PM
    #12
    VanCity4x

    VanCity4x [OP] Straight out of welds

    Joined:
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    DJ
    BC
    Vehicle:
    05 Prerunner
    Hover truck
    Thanks man, put a lot of work into it.

    It was difficult to measure out the spacing for crossmember and I was still a little bit off. I spend at least 10 hours cutting and welding it. My advice, buy the 4x4 tail housing and inchworm adapter, would make it a lot easier.

    The FJ tcase is also very difficult to install on a automatic, the shifter comes up right underneath the transmission shifter. I'm working on fitting my twin sticks, another very difficult process, have gone through 3 different figments for sticks and still doesn't fit right, will prob take a few days more. :annoyed:


    Thanks bro, it totally is. :cool:
     
  13. Aug 3, 2013 at 8:46 PM
    #13
    VanCity4x

    VanCity4x [OP] Straight out of welds

    Joined:
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    Gender:
    Male
    First Name:
    DJ
    BC
    Vehicle:
    05 Prerunner
    Hover truck
    [​IMG]

    Changed coolant, front/rear diff fluid, changed tcase to synth, engine oil, bled brakes and added tranny fluid, was a bit low.
     
    Last edited: Aug 20, 2013
  14. Aug 20, 2013 at 10:53 PM
    #14
    VanCity4x

    VanCity4x [OP] Straight out of welds

    Joined:
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    #60970
    Messages:
    1,393
    Gender:
    Male
    First Name:
    DJ
    BC
    Vehicle:
    05 Prerunner
    Hover truck
    Molybdenite Peak - South of Lillooet BC. 9000 ft elevation, has snow 10 months a year.

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    Last edited: Aug 20, 2013
  15. Aug 20, 2013 at 11:06 PM
    #15
    VanCity4x

    VanCity4x [OP] Straight out of welds

    Joined:
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    Gender:
    Male
    First Name:
    DJ
    BC
    Vehicle:
    05 Prerunner
    Hover truck
    Whipsaw - Princeton, BC off Crowsnest Hwy

    [​IMG]

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    Memorial Rock

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    Falcon Hill

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    IFS Ledge

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    Death Hill

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    Sliders Work :D

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    Coalmont Haunted Hotel

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  16. Aug 25, 2013 at 4:26 PM
    #16
    ChamYota

    ChamYota AKA Crash Bandicoot

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    Cam
    Clemson,South Carolina
    Vehicle:
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    H1 Morimoto projector with XB35 4300K bulbs with Mini-gatling gun shrouds, BHLM. Debadged,OEM roof rack,TW sticker,Sockmonkey Beside decals,265/70/16 Nitto terra grapplers with dick cepek DC'2 wheels,weathertech floor liners(front/back),USA Spec Ipod reader,Scanguage II,Bestop Supertopper and more in the works...
    Holy guacamole, I needed this build for my inspiration, I too have a prerunner. I want to convert it to 4x4; it's already paid for and it was a gift from my parents so trading it in for another truck isnt an option.

    I have no clue how much it'll cost but it's gonna be a ways down the road till i attempt it. Thanks for the build, DSM setting the standard. :thumbsup:

    p.s. My truck is DSM as well :cheers:
     
  17. Aug 25, 2013 at 6:04 PM
    #17
    VinnyMack

    VinnyMack Well-Known Member

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    Buda, Tx
    Vehicle:
    07' PreRunner DC LB
    Brute Force Hybrid w/ custom Longhorn cutout, Satoshi w/ Hella 500's, Wet Okole's, Kenwood DDX419 CD/DVD Player, Fog Lamp Mod, BHLM, Blacked-out badges/grill/roof/valence, 5100's up front @ 1.75, 1.25" Spidertrax, TacomaWorld Sticker, extra D-Rings and custom bed mat, interior LED lighting, and Car Seat Mod.
    Badass, great job man!
     
  18. Aug 26, 2013 at 10:51 PM
    #18
    VanCity4x

    VanCity4x [OP] Straight out of welds

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    Hover truck
    Thanks guys, still have to put togeather a more detailed description of the swap along with finishing the still long list of things that need to be done. :rolleyes:For me it was cheaper then selling and buying another so its def possible for you Cham.

    Heres video from Molybdenite trip

    http://youtu.be/s8FC9y_CU8A
     
  19. Sep 1, 2013 at 6:56 PM
    #19
    Slimwood Shady

    Slimwood Shady I love your mom!

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    Hampton, VA
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    Tough as woodpecker lips...
    Icon Ext Travel COs w/700lb King ID springs Icon VS 2.0 Rear Shocks All-Pro Expo Leaf Pack TC UCA Retrofit Headlights Wet Okles Weathertech Floor Mats TRD Exhaust ATO rear bumper w/swing out tire carrier ARB bumper Smittybilt XRC8 ATO IFS, Tranny, Transfer, and gas tanks skid 4x Innovation DOM sliders w/kickout
  20. Sep 1, 2013 at 7:08 PM
    #20
    RockyMtnTRD

    RockyMtnTRD McBuckets

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    Colorado
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    35 Toyo RT, BAMF Towers + Sliders, Brute HC w/table + Hybrid Front, King 12.0, Alcan Springs, TC Upper
    Hell yeah. Nice build man
     
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