Author Topic: BigMike's Big Journey: A 2016 Tacoma Build Thread  (Read 561474 times)

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BigMike

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April 24, 2017: World's First Dual Case 3rd Gen Crawler is installed!

CHECK IT OUT!! Test-fit pics of the World's first Dual Case'd 3rd Gen Tacoma!







Check out our new Rock Crawling Videos!
2016 56-speed 580:1 Tacoma Rock Crawler   
1981 36-speed 511:1 3RZ-FE Rock Crawler
1987 6-speed Supercharged 4A-GZE MR2
Instagram: @SlowestTacoma
Things are only impossible until they are not.
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"An informed question. But difficult to answer. I am what you see." -Nanaki

R.DesJardin

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Great overview on the Marlin story. I too lived through that time wheelin era and saw all the Toyotas were mall crawlers, lots of chrome. All my friends wheeled flat fender Jeeps. Me? well I had a different Japanese make that I built up. Early to mid 80's timeframe.

So you'll have the range box, 1.1 or 4.7, and the rear case with still work as stock? Until you do the LC case where you case twin stick the rear of course.
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Seems like there is a lot of weight out past the cross-member. Is the plan for a second cross-member to support it?

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Hot damn!
2007 GMC Yukon SLT Daily
5.3L V8, 3.5in Lift, 33X10.5R18 Toyo MTs, Vision Rocker 18x9s powdercoated Mountain Blue Transparent over Speedboat Aluminum

2010 Chevy Tahoe LT Wife's Daily
5.3L V8, 6in Lift, 35s, AMP power steps

2016 Ford F250 XLT CCLB Work/Business Truck
6.2L V8

2001 Ford F350 Lariat CCLB Work/Business Truck
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Instagram @ taytershubby13

BigMike [OP]

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Great overview on the Marlin story. I too lived through that time wheelin era and saw all the Toyotas were mall crawlers, lots of chrome.
I remember the time where if you didn't have dual front shocks then you weren't hot stuff :yupyup:

So you'll have the range box, 1.1 or 4.7, and the rear case with still work as stock? Until you do the LC case where you case twin stick the rear of course.
I am going to keep my Tacoma t/case and the factory push knob for 4WD & Low Range.

Clearance issues

To check for clearance we reattached the drivetrain in it's original location of crossmember to transmission tail housing.

It turns out there are only two issues.

1. T/case top is contacting the bottom of the cab where the e-brake cables are held:



2. The top of the t/case front output section is not touching but is very close to a body rail:



All things considered that is really not bad at all, even the (dumb) factory crossover exhaust clears. As for Triples......forget about it. I am going to have to cut out and replace an entire section of the body. I must go Triples. I will go Triples. I'll have to save that for a later date.

Because I'll eventually be cutting this stuff out I just told Rocky to "use a big hammer" and appropriate clearancing was performed :D We test fitted it three or fours times taking measurements each time so now we know how far to clearance for clean customer installs.



Seems like there is a lot of weight out past the cross-member. Is the plan for a second cross-member to support it?
There are two upsides for weight concerns: 1) The Chain Drive is almost 20 lbs lighter than the older Gear Drive t/case and it's long been proven that one t/case mount is sufficient for the extra weight and length added by a Dual Case setup, and 2) because the #1/front gear drive housing is where the t/case cross member was originally mounted, the Marlin Crawler adds an optional/additional t/case mount. As such there are many crossmembers designed for the Marlin Crawler that incorporate dual crossmember mounts to help spread the drivetrain load prolonging the life of your engine mounts.
Check out our new Rock Crawling Videos!
2016 56-speed 580:1 Tacoma Rock Crawler   
1981 36-speed 511:1 3RZ-FE Rock Crawler
1987 6-speed Supercharged 4A-GZE MR2
Instagram: @SlowestTacoma
Things are only impossible until they are not.
"The worst of both worlds, the best of neither." -abnormaltoy
"An informed question. But difficult to answer. I am what you see." -Nanaki

BigMike [OP]

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April 27, 2017: Temporary Shifter Install

Next we did a temporary shifter install through my front cup holder. As mentioned earlier, I will be designing a proper remote shifter setup that won't require the loss of a cup holder. I'll need this anyway once the Triple Crawler gets installed. So with Cruise Moab only five days away we really just needed to get some miles on this baby so here goes



I first checked for center console availability (dealer says no problem) (I can't just walk into a wrecking yard for this truck) then had Rocky proceed with the install. A traditional dog-leg shifter was fab'd up out of a 22R(-E) 4cyl head bolt (homage!) and trimming was done only what was necessary so that the cup holder will still be functional once I remove and find a better setup for the shifter.

Even if I don't keep this configuration I was amazed to see plenty of open room here for extra shifters. It's always different between cab configs and shift types, with or without rear passenger climate control such as a 4Runner. Hot water lines and heat exchangers. We've built shifter setups for them all -- see our Shifter Gallery Page here -- but having a nice remote setup that could be mounted in more locations would be welcomed. 



The red shift base is our new Push-N-Turn top shift shifter base kit: https://www.marlincrawler.com/transfer-case/shifter-parts/push-n-turn-shifter-base-kit



The outcome was not too shaby!





The next day I replaced the red rag with a black vinyl sound-deadening mat. No shift handle boot. Hoping to have a good winter to get this redesigned and Triples in!
Check out our new Rock Crawling Videos!
2016 56-speed 580:1 Tacoma Rock Crawler   
1981 36-speed 511:1 3RZ-FE Rock Crawler
1987 6-speed Supercharged 4A-GZE MR2
Instagram: @SlowestTacoma
Things are only impossible until they are not.
"The worst of both worlds, the best of neither." -abnormaltoy
"An informed question. But difficult to answer. I am what you see." -Nanaki

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I'd rather see a :turtle: shift knob sticking out of my cup holder than a big gulp ANY DAY :gap:
:)bestgen4runner [12:45 PM]:   I am so stupid.

Truer words have never been spoken...

R.DesJardin

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Does the cup holder come apart so you can make an "billet" aluminum insert that will house/cover all you current and future levers?
R.DesJardin
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When you go to a triple setup, will you move the shifters forward to the tranny  so you have

triple shifters for your triple boxes ?
Ed
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31x10.50R15

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Hey Mike,

Incredible write-up!  Love the photos.

Have you calculated the fuel mileage by the gallons of gas pumped and recording the mileage on the odometer.... or just going by the instrument panel?

Gnarls.
1986 XtraCab SR5 22RE 5speed W56B, ~16,000 MI after break-in, DIM (Did It Myself) rebuilt engine - .020" over, engnbldr RV head, OS valves, 261C cam, DT Header. https://imgur.com/oACTHTR

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BigMike [OP]

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Does the cup holder come apart so you can make an "billet" aluminum insert that will house/cover all you current and future levers?
I was hoping for this at first but unfortunately it is a one piece molded console.

When you go to a triple setup, will you move the shifters forward to the tranny  so you have

triple shifters for your triple boxes ?
The idea is to go entirely away from the traditional shifter arrangement, perhaps use a cable (easiest) or electric solenoid (very cool, but after having used the factory electric t/c shift solenoid it takes a comparatively long time to shift and you don't get that positive physical gear change acknowledgement). 

Hey Mike,

Incredible write-up!  Love the photos.
Thank you! A lot of this has been rushed but once I get caught up I'll actually start trying to take better quality pictures.

Have you calculated the fuel mileage by the gallons of gas pumped and recording the mileage on the odometer.... or just going by the instrument panel?
I track MPG for my vehicles by phone app and yes they are 100% accurate to the MPG dash readout. That said, what I have not done is tracked miles by GPS to verify the odometer. The speedometer is (was) accurate to my GPS.
Check out our new Rock Crawling Videos!
2016 56-speed 580:1 Tacoma Rock Crawler   
1981 36-speed 511:1 3RZ-FE Rock Crawler
1987 6-speed Supercharged 4A-GZE MR2
Instagram: @SlowestTacoma
Things are only impossible until they are not.
"The worst of both worlds, the best of neither." -abnormaltoy
"An informed question. But difficult to answer. I am what you see." -Nanaki

BigMike [OP]

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April 30, 2017: Extended shift solenoid wiring

Because we are adding the TacoBox in front of the t/case, the t/case is moved back. The front driveline must be lengthened, the rear driveline shortened, and wires to the shift solenoid extended.

My truck has 9 wires to extend. A couple second gen automatic-type t/cases we have use 12.



We are working on a pig tail harness so this can (optionally) be a plug-n-play affair.



Wires only need to be extended 8-inches but I extended mine almost twenty to be prepared for Triples



I then re-loomed, taped up, and rerouted using factory loom holders/clips.

May 1, 2017: New drivelines installed

The rear driveline is a two piece with carrier bearing, and while we do have the option to go one-piece, the carrier bearing arrangement keeps the rear d-line up and out of the rocks so I've kept it for now. (Will most likely go one-piece with Triples.)



Front d-line lengthened (pics before looming/mounting wires).



We normally only balance rears, because why would you need to go over 30 MPH in 4WD, but things are different nowadays with expedition and overland use so we'll be balance many fronts. I'll balance mine but no sense doing that yet as it'll get lengthened again.

At this point the Marlin Crawler is all done and ready for its first action!
Check out our new Rock Crawling Videos!
2016 56-speed 580:1 Tacoma Rock Crawler   
1981 36-speed 511:1 3RZ-FE Rock Crawler
1987 6-speed Supercharged 4A-GZE MR2
Instagram: @SlowestTacoma
Things are only impossible until they are not.
"The worst of both worlds, the best of neither." -abnormaltoy
"An informed question. But difficult to answer. I am what you see." -Nanaki

BigMike [OP]

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April 26, 2017: Rear ARB installed

During this time we *finally* got ahold of the new rear ARB Air Locker for non-E-locking 3rd gen Tacomas. Cosmetically it looks very similar to the 2nd gen Taco rear ARB.

So out came the rear diff and in went the ARB.






I now have ARB air lockers front & rear......however at this time I don't have on-board air and nothing hooked up. With only a couple days left before we leave for Utah I plugged off the air lines at each diff and crossed my fingers that my Auto LSD will hold up.

I'll be doing an indepth description and report once I get my on-board air installed and the lockers hooked up.
Check out our new Rock Crawling Videos!
2016 56-speed 580:1 Tacoma Rock Crawler   
1981 36-speed 511:1 3RZ-FE Rock Crawler
1987 6-speed Supercharged 4A-GZE MR2
Instagram: @SlowestTacoma
Things are only impossible until they are not.
"The worst of both worlds, the best of neither." -abnormaltoy
"An informed question. But difficult to answer. I am what you see." -Nanaki

BigMike [OP]

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May 2, 2017: Fender trimming & my first ever Turtle Hood sticker!

One day before Moab I finally got my fenders trimmed for the larger 33s rubbers. We only trimmed as lil as needed for now because we must make entirely new cab mount brackets for the 37s/39s to come soon.

The tires are kept on and suspension cycled after each small cut to recheck interference.



I also got some Spidertrax 1.25" wheel spacers installed to help get my front width back closer to stock (the further you extend a lower A-arm down below horizontal (more lift) the more narrow the front width becomes).



Check out our new Rock Crawling Videos!
2016 56-speed 580:1 Tacoma Rock Crawler   
1981 36-speed 511:1 3RZ-FE Rock Crawler
1987 6-speed Supercharged 4A-GZE MR2
Instagram: @SlowestTacoma
Things are only impossible until they are not.
"The worst of both worlds, the best of neither." -abnormaltoy
"An informed question. But difficult to answer. I am what you see." -Nanaki

BigMike [OP]

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Hood Sticker install

Hmmmmm Something is missing....



Ohh that is MUCH better :D



For the first time in my life I now have a rig with our Turtle Hood Sticker!! WOOOOOT



Take THAT you old lame fake hood scoop lol

Our hood stickers measure 36-inches and may be found here: https://www.marlincrawler.com/accessories/stickers-logos/turtle-stickers

It was easy to install:
1. Clean (degrease) hood
2. Spray soapy water using a mist spray bottle
3. Place sticker atop soapy water and reposition as needed
4. Use a credit card or flat plastic surface to squish all the water out
5. After 30 min or so it will be fully dry and might I say most beautiful
Check out our new Rock Crawling Videos!
2016 56-speed 580:1 Tacoma Rock Crawler   
1981 36-speed 511:1 3RZ-FE Rock Crawler
1987 6-speed Supercharged 4A-GZE MR2
Instagram: @SlowestTacoma
Things are only impossible until they are not.
"The worst of both worlds, the best of neither." -abnormaltoy
"An informed question. But difficult to answer. I am what you see." -Nanaki

BigMike [OP]

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May 3, 2017: Finally back outside!

Finally back outside!



I replaced the 6" Turtle sticker I had installed outside of the Magnolia Market, Waco, TX a year ago with a larger 12" version. (I hastily did it; Should have used soapy water to remove air bubbles.) I also slapped on a TLCA sticker to show my support to the largest international Toyota off-road organization



May 4, 2017: Packing for it's second Cruise Moab event

Over the years I've put together a good trail use and recovery gear that I've had down to a science. All the common issues I see on the trail I've packed and prepared for. But now most of this is out the window as I'm not in my Hilux. Feels reallllllly strange trying to pack for my first real wheel'n event.

This is my usual gear that I bring with me.

With the Tacoma I can place my packers together widthwise. Not possible with the more narrow Hilux bed...



I also have this extra dead space behind my boxes...



Plus I haven't even used this new awesome weather and theft proof space either...



Man there is so much more room here. No wonder these Tacomas are so much larger and heavier....
Check out our new Rock Crawling Videos!
2016 56-speed 580:1 Tacoma Rock Crawler   
1981 36-speed 511:1 3RZ-FE Rock Crawler
1987 6-speed Supercharged 4A-GZE MR2
Instagram: @SlowestTacoma
Things are only impossible until they are not.
"The worst of both worlds, the best of neither." -abnormaltoy
"An informed question. But difficult to answer. I am what you see." -Nanaki

BigMike [OP]

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May 4, 2017: 2nd trip to TLCA's Cruise Moab

Finally leaving for Moab!

All loaded up and ready for another 14 hr road trip!



One last sexy pic before hit'n the road



I couldn't make it five miles on the freeway when this white 3rd gen caught up and began cruising behind me. Queue Jerry Reed's 'East Bound and Down' music!!



Ohh man I'm love'n this hood sticker



Fuel mileage has dropped due to larger tires and lift plus my speedometer is reading 4 to 5 MPH too low. 14.9 is probably really 15.5 or so...

Check out our new Rock Crawling Videos!
2016 56-speed 580:1 Tacoma Rock Crawler   
1981 36-speed 511:1 3RZ-FE Rock Crawler
1987 6-speed Supercharged 4A-GZE MR2
Instagram: @SlowestTacoma
Things are only impossible until they are not.
"The worst of both worlds, the best of neither." -abnormaltoy
"An informed question. But difficult to answer. I am what you see." -Nanaki

THK Matt

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:popcorn: inspiration.
2007 GMC Yukon SLT Daily
5.3L V8, 3.5in Lift, 33X10.5R18 Toyo MTs, Vision Rocker 18x9s powdercoated Mountain Blue Transparent over Speedboat Aluminum

2010 Chevy Tahoe LT Wife's Daily
5.3L V8, 6in Lift, 35s, AMP power steps

2016 Ford F250 XLT CCLB Work/Business Truck
6.2L V8

2001 Ford F350 Lariat CCLB Work/Business Truck
7.3L Powerstroke w/ Banks Turbo

Instagram @ taytershubby13

R.DesJardin

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I have cable shifters for my dual case setup. I found it was a pain for cable routing, bend radius and all, 3 cables, imagine 5. Just saying. I have pics in a thread on here. Air would be sweet, but then you have to add a bunch of control solenoids and an air supply to get it to do what you want. I like the cable idea because you still have the feel and a direct connection to the cases. No wondering if its shifting. Local kid has that setup on his 4Runner, well he actually just sold it. Carry on, I'm enjoying this build up.
R.DesJardin
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May 4, 2017: 2nd trip to TLCA's Cruise Moab

Finally leaving for Moab!

All loaded up and ready for another 14 hr road trip!



One last sexy pic before hit'n the road



I couldn't make it five miles on the freeway when this white 3rd gen caught up and began cruising behind me. Queue Jerry Reed's 'East Bound and Down' music!!



Ohh man I'm love'n this hood sticker



Fuel mileage has dropped due to larger tires and lift plus my speedometer is reading 4 to 5 MPH too low. 14.9 is probably really 15.5 or so...



why does your speedo say 0mph on a busy freeway?  :headscratch:
2007 GMC Yukon SLT Daily
5.3L V8, 3.5in Lift, 33X10.5R18 Toyo MTs, Vision Rocker 18x9s powdercoated Mountain Blue Transparent over Speedboat Aluminum

2010 Chevy Tahoe LT Wife's Daily
5.3L V8, 6in Lift, 35s, AMP power steps

2016 Ford F250 XLT CCLB Work/Business Truck
6.2L V8

2001 Ford F350 Lariat CCLB Work/Business Truck
7.3L Powerstroke w/ Banks Turbo

Instagram @ taytershubby13

emsvitil

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May 2, 2017: Fender trimming & my first ever Turtle Hood sticker!

One day before Moab I finally got my fenders trimmed for the larger 33s rubbers. We only trimmed as lil as needed for now because we must make entirely new cab mount brackets for the 37s/39s to come soon.

The tires are kept on and suspension cycled after each small cut to recheck interference.


I also got some Spidertrax 1.25" wheel spacers installed to help get my front width back closer to stock (the further you extend a lower A-arm down below horizontal (more lift) the more narrow the front width becomes).



[



Don't the wheel spacers make it MORE likely that the outer edge of the tire will hit the fender when turning the wheel ?

 :dunno:
Ed
SoCal
86 SR5 XtraCab
22RE  W56B
31x10.50R15

THK Matt

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votes in, fenderless and 54's :willynilly:
2007 GMC Yukon SLT Daily
5.3L V8, 3.5in Lift, 33X10.5R18 Toyo MTs, Vision Rocker 18x9s powdercoated Mountain Blue Transparent over Speedboat Aluminum

2010 Chevy Tahoe LT Wife's Daily
5.3L V8, 6in Lift, 35s, AMP power steps

2016 Ford F250 XLT CCLB Work/Business Truck
6.2L V8

2001 Ford F350 Lariat CCLB Work/Business Truck
7.3L Powerstroke w/ Banks Turbo

Instagram @ taytershubby13

THK Matt

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and, you guys should produce a billet RF1A housing already clearanced for the 23-spline. ALL RED
2007 GMC Yukon SLT Daily
5.3L V8, 3.5in Lift, 33X10.5R18 Toyo MTs, Vision Rocker 18x9s powdercoated Mountain Blue Transparent over Speedboat Aluminum

2010 Chevy Tahoe LT Wife's Daily
5.3L V8, 6in Lift, 35s, AMP power steps

2016 Ford F250 XLT CCLB Work/Business Truck
6.2L V8

2001 Ford F350 Lariat CCLB Work/Business Truck
7.3L Powerstroke w/ Banks Turbo

Instagram @ taytershubby13

Willard

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Sounds like the wheels spacers were installed to keep the stock width due to the loss from the control arm upgrades.


Sent from my iPhone using Tapatalk
90'4runner......lots of goodies.

V-Man

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Seems like there is a lot of weight out past the cross-member. Is the plan for a second cross-member to support it?

Maybe a combo cross-member skid plate. :thumbs: :yesnod:
« Last Edit: Jun 04, 2017, 06:12:07 AM by V-Man »

V-Man

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To check for clearance we reattached the drivetrain in it's original location of crossmember to transmission tail housing.

It turns out there are only two issues.

1. T/case top is contacting the bottom of the cab where the e-brake cables are held:



2. The top of the t/case front output section is not touching but is very close to a body rail:




sounds to me like a simple 2" body lift will fix that.  With the body lift you can solve three problems at once. Two problem you have now and prevent a problem you can have in the future.  The body lift will give you clearance for the drive line and tires. Since you have the body off the frame change the rubber body mounts and install POLY  body mounts and you will never have to worry about the rubber ones rotting off. 
I also like the feel of the poly mounts.

BigMike [OP]

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have pics in a thread on here. Air would be sweet, but then you have to add a bunch of control solenoids and an air supply
Not a fan at all for air shifting due to too many requirements, complexity, and maintanence on the customer's end. I will take a look at your thread. We've done cable shifters before many times on ToyBoxes (Land Cruiser Dual Case setups) with success.

why does your speedo say 0mph on a busy freeway?  :headscratch:
The 3rd gen Tacoma looks so cool that other motorists are willing to hold up traffic for this Build Thread :greengrin:

Don't the wheel spacers make it MORE likely that the outer edge of the tire will hit the fender when turning the wheel ?
Yes and it'll get worse once I go at least another two inches wider per side (AP's long travel IFS kit).

and, you guys should produce a billet RF1A housing already clearanced for the 23-spline. ALL RED
The cost of that large a billet! :o :o

Maybe a combo cross-member skid plate. :thumbs: :yesnod:
Yessir, I've already got it half drawn up and hopefully will have something ready by Rubicon early July.

sounds to me like a simple 2" body lift will fix that.
In my experience bandaids like body lifts only cause more problems elsewhere. I highly dislike body lifts and only made a 1" kit for my Hilux because I thought it was required for the 3RZ-FE conversion. I was wrong. Bumpers since welded to the frame. Not gonna go back now.

This is what comes to mind when I hear the words "body lift" :ha_ha:
Check out our new Rock Crawling Videos!
2016 56-speed 580:1 Tacoma Rock Crawler   
1981 36-speed 511:1 3RZ-FE Rock Crawler
1987 6-speed Supercharged 4A-GZE MR2
Instagram: @SlowestTacoma
Things are only impossible until they are not.
"The worst of both worlds, the best of neither." -abnormaltoy
"An informed question. But difficult to answer. I am what you see." -Nanaki

BigMike [OP]

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May 4, 2017: 2nd trip to TLCA's Cruise Moab

Misc driving pics. I forgot to mention how I couldn't get the Taco ready until a day after Marlin and Mrs. Crawler had already left for Moab. So I made the 860 mile solo trip in one shot. I'll tell you one thing, having a truck newer than 1983 that has cruise control is very helpful.

Grabbing lunch in Las Vegas. Haha just noticed I had parked on the line





One entire tank straight without stopping. A 5 to 6% change in speed reading would make it 306-309 miles traveled at 15.4 to 15.6 MPG.





Drowsy driving? No wonder...


Check out our new Rock Crawling Videos!
2016 56-speed 580:1 Tacoma Rock Crawler   
1981 36-speed 511:1 3RZ-FE Rock Crawler
1987 6-speed Supercharged 4A-GZE MR2
Instagram: @SlowestTacoma
Things are only impossible until they are not.
"The worst of both worlds, the best of neither." -abnormaltoy
"An informed question. But difficult to answer. I am what you see." -Nanaki

BigMike [OP]

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May 4, 2017: 2nd trip to TLCA's Cruise Moab

Safely arrived back in Moab!





Check out our new Rock Crawling Videos!
2016 56-speed 580:1 Tacoma Rock Crawler   
1981 36-speed 511:1 3RZ-FE Rock Crawler
1987 6-speed Supercharged 4A-GZE MR2
Instagram: @SlowestTacoma
Things are only impossible until they are not.
"The worst of both worlds, the best of neither." -abnormaltoy
"An informed question. But difficult to answer. I am what you see." -Nanaki

V-Man

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In my experience bandaids like body lifts only cause more problems elsewhere. I highly dislike body lifts and only made a 1" kit for my Hilux because I thought it was required for the 3RZ-FE conversion. I was wrong. Bumpers since welded to the frame. Not gonna go back now.

This is what comes to mind when I hear the words "body lift" :ha_ha:

You  have hurt my feelings...  :snare:

Also that is not a body lift. That is something with words I can't use here and not get banned for this life and maybe
 the next.. :smack: :reg: :screwy:

 
 
 
 
 

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