84 4Runner Buildup - Last minute summer mods

[83 Crawler]

 

just read threw the hole build, gave my friend inspiration to build his for sure!!! sick truck man!

[Matty]

Finally broke down and bought some soft bumpstops to get rid of the rock hard TG ones I've been running for 4 years now.  Marlin had these Daystar poly bumpstops on sale a couple of weeks ago for $45. 

niice!      those TG ones sucked.  thought my teeth were gonna fall out everytime it slammed into them. 

[Volcom]

just read threw the hole build, gave my friend inspiration to build his for sure!!! sick truck man!

Thanks!

niice!      those TG ones sucked.  thought my teeth were gonna fall out everytime it slammed into them. 

I've never felt a harder bumpstop than those TG's.  I should have just put some steel stops in there, would have felt the same, hahahahahaha.  Did you get your truck up and running yet Matty?  Stay tuned for this year's Jambo dates and info!

[Montana300]

Where do you guys get your turbos?

[Volcom]

Where do you guys get your turbos?

Mine isn't turbo'd.  The red 86 is a factory 22RET.  I believe he's still running the factory turbo.

[Volcom]

The Race to Moab - 2011

Decided to start tearing down the 4Runner to get it ready for Moab in 3 weeks.  I noticed some drivetrain vibs while snowbashing with DIRTCO in Breck earier this year.  Same with snowbashing with my buddy Brandon last weekend.  So I pulled the cases to check them out along with install my new twin stick.



Got the cases out


Trying not to make a mess but anytime I'm working with gear oil, it's bound to happen


Have to remove the reduction box from the rear case to install the twin stick




Not good.  Found a loose ball bearing from the bearing around the coupler     That's probably my driveline vibration.

So, I called my buddy Joe and he's got the same dual case adapter (10 degree rotated version though) and I was going to take the bearing from his adapter.  My adapter must be old because it looks nothing like his adapter.  I'm hoping the bearings are the same.  I'll be calling Marlin in the morning to see if I can swap the bearings without issues and to order a new bearing.  Not really what I was hoping to see 3 weeks before Moab.

[COToy91]

Thats not good. Good thing you were able to source a bearing from your buddy.

[PhantomD aka Zach]

call marlin about it, I had a similar issue and it ended up being a known problem with the bearing manufacturer.

I just finishing re-bearing my case, bought the inchworm kit, to replace the JOKE of the TG kit I first bought.

I re-did the bearings since the failed adapter bearing introduced a bunch of filings into the case and the bearing surfaces were pitted.

-Zach

[Volcom]

I did, called and left a VM and also sent "Blue" a PM about it. 

[Volcom]

Freds40's taking care of me, thanks Marlin Crawler!!

[Volcom]

call marlin about it, I had a similar issue and it ended up being a known problem with the bearing manufacturer.

I just finishing re-bearing my case, bought the inchworm kit, to replace the JOKE of the TG kit I first bought.

I re-did the bearings since the failed adapter bearing introduced a bunch of filings into the case and the bearing surfaces were pitted.

-Zach

Yup, they are sending me out a bearing.  I think I caught mine quickly so I shouldn't have to do anything else but replace the bearing and clean up the cases.  I saw your bearing pictures and my looked nothing like that.  I think mine not being a DD helped since it hasn't seen very many miles on it.

[PhantomD aka Zach]

Marlin kicks ass!!! He definitely takes care of his customers.

Glad to hear you are not going to have any issues.

Hopefully I will make it to the jambo, but my summer is packed.

[Volcom]

Marlin kicks ass!!! He definitely takes care of his customers.

Glad to hear you are not going to have any issues.

Hopefully I will make it to the jambo, but my summer is packed.

I agree, I've been happy with every Marlin product I've bought.  As for the issues, I hope not to run into anymore but in 18 days, who knows

You've gotta make the Jambo!  It's by far the best wheeling weekend of the year.  Just the campfire stories at night are worth it, hahahahahahaaha

[yotatough]

how old is your adapter? I havent heard of this problem and am worried now about mine....

[wakkjobb]

 

Good save! Hope your Moab trip is trouble-free too, take millions of pics to get us motivated to work on our piles... or to make us jealous. 

>>Dan

[Volcom]

how old is your adapter? I havent heard of this problem and am worried now about mine....

January 2007.  I think Marlin had a bad batch of bearings in that time period.  They have bent over backwards so far to get me a replacement bearing to make my trip on time.

Good save! Hope your Moab trip is trouble-free too, take millions of pics to get us motivated to work on our piles... or to make us jealous. 

>>Dan

Will do.  I've got a 16GB card in the camera and plan on taking as many pictures as I can each day and loading them to my laptop to free up the camera card for more pictures and video

[Volcom]

Made some great progress this weekend.  My old crossmember only mounted to the front t-case (rather than both cases).  I decided to step up to new crossmember that attached both cases.  The forces those mounts see is unreal with dual cases.  It didn't help that the t-case mount was loose and striped 3 of the 4 bolts holding it on.  I'm guessing that was the majority of my driveline noise.

New dual case crossmember skid plate from Addicted Off Road showed up Friday. 50 pounds of 3/8" thick press bent steel      My bearing from Marlin showed up Saturday.  Thanks again for sending a new bearing out Marin Crawler!!


Cases out and apart, just waiting for the bearing.  Might as well start tearing down the front axle for a rebuild and knuckle swap.


My 35" rollers and 39.5" Iroks


Trying to keep all the nasty gear oil mixed with grease (Birfield soup) off the garage floor.


I still need to tear the other side down.


New crossmember from Scotty at Addicted.


Got the shift fork interlock pin out and the twin stick installed.  Going to be nice to have 2wd low for the trail.  I might actually make a couple corners that I used to have to 2-3-4 point turn   


The messy garage.  Lots of room to work though!


Dual cases back together.  I had to buy all new hardware for the t-case mounts.  $1.50 a bolt x 8.  Red locktited them in so they don't come loose anymore.


As far as I got tonight.  The cases are bolted down to the crossmember but I'm having touble getting the driver's side frame mounts to line up with the crossmember.  Good time to stop for the night.


Jack holding up the drivetrain for now.

Stuff to get done before Moab
Get the crossmember fully bolted to the frame
Hook up front and rear drivelines
Fill t-cases with oil
Install t-case shifters and rubber boots
Tear down driver's side front axle
Clean up replacement knuckles
Install 5th studs
Pull 3rd member and install differential stud eliminator bolts (ordered from Fastenal, should be here Wednesday)
Red Locktite the damn knuckle studs in so they never come loose again
Reassemble the front axle
Install front lights on bumper
Install rock lights
Fab new bumpstop brackets

[Peterbuilt84]

Just read through the whole build, that is a sweet 4runner There are a ton of good ideas that I wish I would have done in my ow build and some ideas I might have to copy

They may have been covered, but I have a couple questions. What kind of breakage (if any so far) are you having with the 40's? And what is your frame height?

[Volcom]

Just read through the whole build, that is a sweet 4runner There are a ton of good ideas that I wish I would have done in my ow build and some ideas I might have to copy

They may have been covered, but I have a couple questions. What kind of breakage (if any so far) are you having with the 40's? And what is your frame height?

Copy away!

Breakage - I've trashed a couple knuckles because of the knuckle studs loosening up but that could have happened on 35's or 37's.  I finally got that covered with the 5th knuckle studs.  They stayed tight all week in Moab.  I've never had any major breakage with the 40's.  No R&P's as of yet.  Aussie lockers have held up as well.

Frame height at trail pressure (6-7 psi) is 27".  I'm going to work on lowering the 4Runner.  I'd love to have it at 25" but that may be tough. 

[Peterbuilt84]

Thanks for the info   There were a couple times in the build when I thought, why didn't I do that  

I did the 5th stud when I rebuilt my axle. It seems like there haven't been to many complaints and everyone seems to say it's a good mod.

How hard was to set up the heims? Was it worth it? I am going to put on hydro assist and just wanted to see any pointers or opinions from other people on upgrades before I do.

[Volcom]

How hard was to set up the heims? Was it worth it? I am going to put on hydro assist and just wanted to see any pointers or opinions from other people on upgrades before I do.

The setup on the heims was pretty easy.  I had to redo my steering after my hydro ram broke and bent up the tie rod / bump stop and frame on driver's side.  I just ordered up some Midwest Control heims, 1.5" .25 wall tubing, and tubing adapters from Ballistic Fab and built a new tie rod.  The high steer arms needed the hole reamed.  My uncle is a machinist and we did the ream job on his Bridgeport vertical milling machine.  I picked 3/4" bolts because the tapered hole for the FJ80 TRE at the top is pretty much 3/4". 

You might be able to drill the holes but I felt the milling machine was the better method.  Not everyone has access to a milling machine though.

The heims are so easy compared to TRE's.  Removable of the tie rod is now bolts rather than a pickle fork and hammer to get the TRE's out of the steering arms.

About hydro assist - make sure you get the ram as parallel to the tie rod as possible.  Also, make sure you have ample space on the driver's side between the end of the ram and the U bolt plate / bumpstops / etc...  I learned that the hard way. 

[Volcom]

Moab pictures from the end of March


Somewhere on Behind the Rocks


Bottom of White Knuckle Hill


Behind the Rocks












Slick Rock Dome on Moab Rim


Moab from the Moab Rim overlook




Start of Poison Spider


Poison Spider Waterfall


Still on Poison Spider



Moab with the La Sal Mtn range covered in snow


Somewhere on Golden Spike


Golden Crack on Golden Spike trail





Bottom of Hells Gate (drove up it twice )


Bottom of Escalator.  Ended up trying a couple of times before I climbed it.

http://www.youtube.com/watch?v=q3Vk7lcats8&hd=1

http://www.youtube.com/watch?v=s8yiYBuhKvo&hd=1

[Volcom]

Independence / Patriot 6-4-11




Dropping in Indy. Trail was in great shape! Toughest I've seen it in along time.




My turn down Bunker Hill. Took me alot more than 1 try on the right hand turn. My power steering box must be going out. It's super hard to turn right, turns left no problem.


Got to the top of Mike's 49" tire



First section of Patriot



Not bad rear flex for being leaf sprung! I also make it out of A-Hole with no issues.






I also took every line possible on Coffin Rock. I thought I had the far left line at the last second, the rear tire would slip off of the Coffin. Finally took the right line and had to pull winch cable to get out.


The difference between a 39.5" tire and 49" tire 





I made it as far as I felt comfortable on the exit of Patriot. Once the wheelstand got that big and my passenger rear tire still had a 4' undercut ledge to try and climb, I was ready for the winch cable.

[twistedtoy92]

runner's lookin good, cant wait to get mine to moab someday....

[Volcom]

The time has come to finally get this thing painted all one color     My buddy Brandon helped me out big time last Friday night.  He let me use his shop and he helped me DA sand for 5+ hours.  Thanks for all the help Brandon  

What color do you get when you sand a faded out maroon/brown 27 year paintjob?










Knocked out the big dents with an 8lb sledge hammer and a 4x4  

















Nasty purple  
Color will come in a couple weeks.  It will be bright  

[bigarms23]

im painting mine to before the jambo i am using a color called knockoff ferrari blue which looks teal

[Volcom]

im painting mine to before the jambo i am using a color called knockoff ferrari blue which looks teal

Nice!!  Glad you're still coming out for the Jambo!  Let me know if you have any questions regarding the event or Colorado in general.  You coming out for more than just the Fri/Sat/Sun of the Jambo?  Might be able to get you some company out in Penrose (pictures in this thread above).  Let me know!

[twistedtoy92]

So how is your heim joint steering setup holding up? Im doing the same setup but I was planning on running heims on the drag link with a flat pitman arm.... seems like the tie rod ends on my drag link wear out faster than on the tie rod since they have to move up and down a lot more....

[Volcom]

Tear down - Friday night






Time for tape




New $2.89 soft topper




Badass paint booth






It's bright 


























My boy approves 




Shiny paint makes the dents POP!!













I love it and it came out great!  Not bad for a total of $150 of paint and supplies.  Big thanks to my buddy Brandon for the help.  There's no way I could have done this in my garage and without his help.

[COToy91]

paint looks great!