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Vancity4x 1ton SAS

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] The shit show

    Joined:
    Aug 1, 2011
    Member:
    #60970
    Messages:
    1,408
    Gender:
    Male
    First Name:
    DJ
    BC
    Vehicle:
    05 Prerunner SAS
    3link 1tons on 40's and sum stuff
    2005 Prerunner, converted to IFS 4wd and now running 1 Ton axles on 40's. Rock Crawling, camping/expedition and snow wheeling in BC. @VanCity4x on IG for current :canada:

    Here's how she currently sits,

    F472BAA3-6650-4C99-BAD7-0ABBDD8A6E51_zps_5a3660c5eb573cc44bf7dd687d811ad31dfec285.jpg

    3CF2082B-7408-4E1A-BD09-E1D2696945AC_zps_b879b60cf423ef103e06b47066fd3cf18abcafe2.jpg

    8A14DF78-D19E-462E-B5F2-CD660A7A42B1_zps_582a25da1c66f6563e1efa03fa02a549a4e69e5e.jpg

    CB8B541A-325F-4445-8DA6-161422FCE27A_zps_55cf12c48ae9bd0e14527e925e5ed15d2cb9f935.jpg

    5e4a02f633a625c0cfe36501aefddef5_zpszebu_395bc6e7d353d365cf0026d3cc0992ed46b8b668.jpg

    64aa504ab0ca167599c5c2c64de2f3cf_zps2tdt_8bdde0f8cd52a09ef5f68d4323c4f2ba4e755f16.jpg

    95F49CA8-E5FD-4418-83FE-57BEB0900242_zps_80dd01c3be31fe999f8d1ffa403f4e311fd643c1.jpg




    a4630389e83076f137612c5bb52a6962_zps0be7_5dce7ccce3c500bab814b319348072e1e564fa8d.jpg

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    e96c7ea4822e13619a40ce964be85ad8_zps4d43_c2b011b40b7477d25f3098c163cfeab4b8989875.jpg


    Drivetrain:
    04 Ford SD D60 Front
    -Ballistic cover
    -Histeer Arms keyed 6 stud ARP
    -35sp units/stubs
    -Warn hubs
    -JK callipers
    FF 14 Bolt Rear
    -Ballistic shave
    -Eldorado custom disk setup
    Front/Rear ARB lockers
    5.13 Yukon gears
    6x5.5 hubs, ARP Studs, Mcguard lugs
    FJC xfer Front Range twin sticks
    Spicer built driveshaft
    Intake in cab

    Kicks:
    42” Iroks on diy beadlocks
    40” MTR Rock spiders

    Armor:
    Custom Front/rear tube bumpers
    Sliders

    Suspension:
    3 link front w/ Ballistic joints
    14" 2.0 Radflo coilovers
    F911 Hardware

    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
    Hella 4000i xenon Hid’s
    Hella Supertone horns

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

    Audio/Coms:
    Kenwood dd 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

    Progress
    KOH/AZ Rocks/Moab Spring prep
    Rock/rear lighting and fuse box
    50W VHF
    Fiberglass boxsides/rear bumper build
    Softtopper
    Trac bar
    Tundra 2uz V8 build/swap
     
    Last edited: Dec 24, 2015
  2. Jul 6, 2013 at 9:33 PM
    #2
    VanCity4x

    VanCity4x [OP] The shit show

    Joined:
    Aug 1, 2011
    Member:
    #60970
    Messages:
    1,408
    Gender:
    Male
    First Name:
    DJ
    BC
    Vehicle:
    05 Prerunner SAS
    3link 1tons on 40's and sum stuff
    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

    6EFB88AC-D8B6-4998-AF11-021D0462D52C-824_936674f404db48f14626ca00f0a6963f8da2f82f.jpg


    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.

    A81ED30F-F9FF-42DF-8510-4CBC97B2218B-824_e5e441ea43b7618a7290227dc985ce65d02f1062.jpg


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

    2754045E-2249-43EA-92C7-EA5AB18A23ED-824_dfa8fffe48d4bf1676fe71bce09fcf2202ef0ec5.jpg


    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.


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    2737a4d44ea096f89a2717a0dd16870a_zps919e_3a0f4389c8945f7dc77fee101805c1884d5eb702.jpg


    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]

    E6DCD80E-0DF7-4D43-B03E-F3A41F2400A3-824_2df9e2d906d7726881441e5c640b7836529b97c0.jpg


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    7D141751-731C-41D8-BE09-8F220C55605F-824_fc4acef3707b69648daaf95517362743a2156ab0.jpg


    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.

    6fc07230aaa4f944f9d2af3ea07b4677_zps84d0_3b8d88ea80824b0a1bfbcfcef2a1fe3243f22dd8.jpg





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    11C2E892-8F49-45B7-AB10-FDA0ADE65128-824_487d9e0c3e15b3f2cb6a507586a5f834ac60e12b.jpg

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

    DF3083C6-582A-4090-ADCA-C3BAA14F13F4-824_674101591a54a59284750e05098fbb0c19af2963.jpg


    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.

    b8496a9477fb732a7a97e4da7ee22c32_zps17b5_c67e263bf0fcc4443b221d3978001d04be8f9911.jpg

    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]

    6ca94a71b8cf03a8d12d72b842af1ba8_zpsd818_36ff97436fa920fa5ad901ce7f0534fa15f5db4c.jpg
     
    Last edited: Feb 3, 2014
  3. Jul 6, 2013 at 9:33 PM
    #3
    VanCity4x

    VanCity4x [OP] The shit show

    Joined:
    Aug 1, 2011
    Member:
    #60970
    Messages:
    1,408
    Gender:
    Male
    First Name:
    DJ
    BC
    Vehicle:
    05 Prerunner SAS
    3link 1tons on 40's and sum stuff
    1
     
    Last edited: Sep 4, 2015
  4. Jul 7, 2013 at 12:05 AM
    #4
    Stew Fidaso

    Stew Fidaso Member

    Joined:
    May 29, 2013
    Member:
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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
    Member:
    #101146
    Messages:
    4,268
    Gender:
    Male
    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:
    Jul 31, 2012
    Member:
    #83808
    Messages:
    114
    Gender:
    Male
    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] The shit show

    Joined:
    Aug 1, 2011
    Member:
    #60970
    Messages:
    1,408
    Gender:
    Male
    First Name:
    DJ
    BC
    Vehicle:
    05 Prerunner SAS
    3link 1tons on 40's and sum stuff
    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:
    Jul 31, 2012
    Member:
    #83808
    Messages:
    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 Big Member

    Joined:
    Feb 4, 2008
    Member:
    #4570
    Messages:
    6,491
    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:
    May 29, 2013
    Member:
    #105187
    Messages:
    13
    Gender:
    Male
    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 gotta make sure Youtube comes down to tape this

    Joined:
    Apr 12, 2011
    Member:
    #54800
    Messages:
    1,876
    Gender:
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    First Name:
    Garrett
    Vehicle:
    06 DCLB
    OME, ARB, Warn, Snugtop XV
    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] The shit show

    Joined:
    Aug 1, 2011
    Member:
    #60970
    Messages:
    1,408
    Gender:
    Male
    First Name:
    DJ
    BC
    Vehicle:
    05 Prerunner SAS
    3link 1tons on 40's and sum stuff
    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:
     
    mattraptor likes this.
  13. Aug 3, 2013 at 8:46 PM
    #13
    VanCity4x

    VanCity4x [OP] The shit show

    Joined:
    Aug 1, 2011
    Member:
    #60970
    Messages:
    1,408
    Gender:
    Male
    First Name:
    DJ
    BC
    Vehicle:
    05 Prerunner SAS
    3link 1tons on 40's and sum stuff
    [​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] The shit show

    Joined:
    Aug 1, 2011
    Member:
    #60970
    Messages:
    1,408
    Gender:
    Male
    First Name:
    DJ
    BC
    Vehicle:
    05 Prerunner SAS
    3link 1tons on 40's and sum stuff
    Molybdenite Peak - South of Lillooet BC. 9000 ft elevation, has snow 10 months a year.

    320d9c65615c34f3f48b1f36cf7abd6e_zps1b87_59c1497b166f88ba01193a3cc3dce674f1a15b8b.jpg


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

    VanCity4x [OP] The shit show

    Joined:
    Aug 1, 2011
    Member:
    #60970
    Messages:
    1,408
    Gender:
    Male
    First Name:
    DJ
    BC
    Vehicle:
    05 Prerunner SAS
    3link 1tons on 40's and sum stuff
    Whipsaw - Princeton, BC off Crowsnest Hwy

    73af8c29a9326c82c7fe2248341d7eee_zpsb639_48888dd4fbc8c411cba39532f8814b548ccac959.jpg

    3dbd1aa92096dbd0a5ee3f9f6870cf26_zpsde5b_596a714513afc25527f9c23559e3bec5229c6b53.jpg

    Memorial Rock

    a8e97f6ff7490ed65a0f6a7c45370bb7_zps2945_0173cfa9372fc557a8f9c427f419045eccb35b79.jpg

    Falcon Hill

    60370c6ada4be776c393d36dff0006a1_zps79b0_ac971b2335cdf6adf6f93bd5f8fd1a22accceafe.jpg

    03bf33f845be6b311ed3d4cf4a46f270_zpscf13_13a2826b317c22903c7d61bd4352627aab5944f9.jpg

    IFS Ledge

    95516c919fac78e8b109d2359a2ec4fa_zps402c_59ce2041861f77352e6dae3579fa4eb255b139f7.jpg

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    Death Hill

    f5d54266101f1e2f40f32f39be3a1957_zps7f1d_d065edee63441c92c28313b6ffc7e2dbd532b8e3.jpg

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    Sliders Work :D

    86eaf54f734bf9b47e717a9874c89c04_zps7c4f_933017983e9f8c93486ea0c7d3ad030ec40cdc27.jpg

    Coalmont Haunted Hotel

    5cd3c1263880ccbcac5882a0f4d50d84_zpsa080_ca284086897654c4054a7166eec3c8ccee57492b.jpg
     
  16. Aug 25, 2013 at 4:26 PM
    #16
    ChamYota

    ChamYota Crash Bandicoot Or Groot, Just Depends

    Joined:
    Jul 6, 2011
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    #59431
    Messages:
    11,420
    Gender:
    Male
    First Name:
    Cam
    Clemson,South Carolina
    Vehicle:
    05 PreRunner and 2004 Lexus IS300 Sport Design
    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

    Joined:
    Dec 17, 2012
    Member:
    #93284
    Messages:
    269
    Gender:
    Male
    First Name:
    Casey
    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] The shit show

    Joined:
    Aug 1, 2011
    Member:
    #60970
    Messages:
    1,408
    Gender:
    Male
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    DJ
    BC
    Vehicle:
    05 Prerunner SAS
    3link 1tons on 40's and sum stuff
    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
     
    Leppz likes this.
  19. Sep 1, 2013 at 6:56 PM
    #19
    Slimwood Shady

    Slimwood Shady I love your mom!

    Joined:
    Jul 12, 2009
    Member:
    #19585
    Messages:
    10,721
    Gender:
    Male
    First Name:
    Linwood
    Hampton, VA
    Vehicle:
    '17 Tundra; '16 Odyssey; ;14 A4
  20. Sep 1, 2013 at 7:08 PM
    #20
    RockyMtnTRD

    RockyMtnTRD Wanderlust.

    Joined:
    May 4, 2011
    Member:
    #56088
    Messages:
    6,465
    Gender:
    Male
    First Name:
    Noah
    Colorado
    Vehicle:
    '11 TRD OR
    hack job
    Hell yeah. Nice build man
     
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