Bad_Vision's 1985 Toyota 4RUNNER TDI Swap (Completed swap)

Bad_Vision · Dec 10, 2015

Updated: new transplant vehicle is a 1985 4Runner frame with a 1987 pickup cab.
I am currently on the hunt for a donor rust free 4runner to put on this frame. And when I find one I will post pictures of the new 4runner body running the TDI engine.

Bad_Vision · Dec 10, 2015

Here is the power plant donor
2001 Jetta TDI automatic with ALH engine
Got it for $1200 runs and has tranny slip. I will be scrapping left over parts of it in eBay to help fund the project a little bit.

Bad_Vision · Dec 10, 2015

On my way to pick up the 1984 4Runner today that will be the frame for this swap.

Bad_Vision · Dec 12, 2015

Bad_Vision's 1985 Toyota 4RUNNER TDI Swap

Ok after reviewing the 1984 and its issues and the fact that the 96 has a strong engine I'm changing the plan up.

The 1985 will get the TDI.

Have a good weekend I won't be updating till late next week once I start my "vacation".

Here is the articles I have been reading the most to give me ideas and information.

http://www.myturbodiesel.com/wiki/i...ng-for-vw-and-audi-with-key-replacement-tips/

http://www.offroadsolutions.com/tech-info/3-4l-5vz-fe-conversion/

http://d44tech.com/flipped_chevy_dana44.html

http://cutandturn.com/tech.html

http://sonoransteel.com/phong/retrofit_electric_locker.html#safeties

Bad_Vision · Dec 14, 2015

Steel order came in. And started assembling the parts. I have still not found the donor axle yet so thinking I'll cut the tubes of a passenger drop axle and flip the tubes around.

For those of you who have not seen my shop here are some pictures I took today. Unfortunately my dad had a very large project due this week so I can't start frame building till next week [emoji17]

BigRyan1986 · Dec 14, 2015

Nice shop. One day ill have something like that to play in. Till then back to the gravel i go lol. Sounds like an interesting build. I was doing some research on building my Volvo and someone said something about a supra 5 speed swap if you go over 250hp on your engine and that there is a kit. That being said im going to research that and possibly put a volvo turbo engine into my 2nd gen

Bad_Vision · Dec 14, 2015

After doing all the research on diesel swaps with Toyota platforms the TDI was the best option. As a stock direct replace engine in the ALH is almost identical engine specs for horsepower and torque.
That being said with minor CHEAP modifications that motor can put out 150 hp with around 230 foot pounds of torque.

They have some TDI engines that can put out close to 400 hp in over 800 foot pounds of torque that kind of power would of course nap factory Toyota axles like a twig.

I will also be running lifted with 37 inch tires 529 gears
And by most comparison swaps that will still get me close to 30 miles per gallon. So I will not have to give up the daily driver aspect of my toy.

You really need to decide what turbo diesel engine is more suited to your needs.

The OOM 617 is nice but requires a lot of modification to the framework and radiator support.
The 4BT has extra power but it is also extra heavy

All of these engines can be run mechanically as well they do not require any ecu but that cost more money.

in any situation I would recommend buying a running donor vehicle. In my area it was $400 more to buy a running vehicle then just the motor. When all said and done I will sell the parts and make a little bit of money back from the donor vehicles.

flyinhawaiian01 · Dec 14, 2015

HOLY CRAP! That's one large shop alright! Must be twice as big as mine! And I like the 3 axis cnc lathe you got in there! Must be nice to just make your own parts when there's nothing available off the rack!

Bad_Vision · Dec 14, 2015

flyinhawaiian01 said:
HOLY CRAP! That's one large shop alright! Must be twice as big as mine! And I like the 3 axis cnc lathe you got in there! Must be nice to just make your own parts when there's nothing available off the rack!

Thanks it has its advantages and disadvantages. I'm never short of a "friend" that needs something LOL

v_man · Dec 15, 2015

cool project and I'll be looking forward to your build... what do u and your dad do BTW?

Bad_Vision · Dec 15, 2015

My dad owns a machine and fabrication shop. I own a remodeling and custom carpentry company.
He lets me use his building and machines and I fix his house and vehicles. It's a fair trade I think!

Bad_Vision · Dec 15, 2015

Here is a good article I found!
I think I'm going to do this to a factory Toyota front axle I have laying around.

What do you guys think?

http://d44tech.com/flipped_chevy_dana44.html

maclean216 · Dec 15, 2015

why not the dana 60?

v_man · Dec 15, 2015

hard to find and expensive ? at least they are around here...

maclean216 · Dec 15, 2015

Unless its off a 80 series land cruiser, aren't they a little narrow?

Bad_Vision · Dec 15, 2015

Bad_Vision's TDI 1984 build with 1996 SAS build.

Here has what I have found out while researching.
Toyota gear ratio 5.29
Dana axle closest 5.38 or 5.13
Both these ratios are over 1% over tolerated difference, which means this would be very bad for my truck in 4wd. Granted the effect would be only noticeable on pavement but I do want to drive my truck year around and snow on pavement is inevitable and I don't want to make a very costly mistake of forgetting I have mismatched gears and grenadeing my differential or transfer case!

So the best thing for a daily driver is to ether get the outrageously overpriced trail gear $5,000 custom axle [emoji23][emoji23][emoji23][emoji23][emoji23]
Or make a old Toyota axle into what I need.

5.29 with lockers front and rear with true Toyota axles.
The stock Toyota axles are strong enough for my application! And even if I was building a super rock crawler with 44" tires I would never spend $5,000 for a trail gear axle. When I can buy brake rotor to brake rotor unimog axels for half that cost.

Bad_Vision · Dec 15, 2015

maclean216 said:
Unless its off a 80 series land cruiser, aren't they a little narrow?

55.5" front 55" rear

Remember width can be adjusted with wheel spacers without modification to the axels.
2.5" on both sides is stretched out to 5"
And that's not including offset rims to adjust as well. And I wouldn't want it sticking out so far I need crazy fender flares anyway then I can't fit in the narrow areas.

maclean216 · Dec 15, 2015

3rd gen 4runner is ~60" wms to wms.

What about a Jeep JK rubicon front take off? HP, bigger ring and pinon, and wider?

Bad_Vision · Dec 15, 2015

Bad_Vision's TDI 1984 build with 1996 SAS build.

First Gen front axle is 55.5"
So I would have to make up 4.5" in wheel spacer and wheel offset not a big deal.

As for the jeep axle idea it's still a Dana and would not have matched gear ration.

The only other option would be a ford 9" with 5.29 and that would blow the budget almost as bad if I was stupid enough to buy the trail gear axle.

BigRyan1986 · Dec 15, 2015

Bad_Vision said:
After doing all the research on diesel swaps with Toyota platforms the TDI was the best option. As a stock direct replace engine in the ALH is almost identical engine specs for horsepower and torque.
That being said with minor CHEAP modifications that motor can put out 150 hp with around 230 foot pounds of torque.

They have some TDI engines that can put out close to 400 hp in over 800 foot pounds of torque that kind of power would of course nap factory Toyota axles like a twig.

I will also be running lifted with 37 inch tires 529 gears
And by most comparison swaps that will still get me close to 30 miles per gallon. So I will not have to give up the daily driver aspect of my toy.

You really need to decide what turbo diesel engine is more suited to your needs.

The OOM 617 is nice but requires a lot of modification to the framework and radiator support.
The 4BT has extra power but it is also extra heavy

All of these engines can be run mechanically as well they do not require any ecu but that cost more money.

in any situation I would recommend buying a running donor vehicle. In my area it was $400 more to buy a running vehicle then just the motor. When all said and done I will sell the parts and make a little bit of money back from the donor vehicles.

I wasn't thinking about going diesel. Im buying another 240 turbo volvo as a parts car for my 82 and thought if the engine can be bolted to a toyota tranny then why not if i have en extra running engine. It all depends on the condition of the other engine and if i can get it running before i pull it out. If not then it will get built for my volvo. I thought the volvo 4 cyl turbo swap would be different and cool like this build you are doing.

Bad_Vision's 1985 Toyota 4RUNNER TDI Swap (Completed swap)

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