[papabeach]

1999 TOYOTA 4RUNNER SR5 HIGHLANDER
(SC'd, Lifted, Dual Cased, Dual Locked, Geared, Armored, MT-R452d and more...)

Upgrades & Modifications:

Engine & Performance:

OEM 1999 5VZ-FE 3.4L V6

Forced induction:
TRD 2nd Gen Supercharger (complete rebuild by Magnuson S/C ~150K)
URD 2.2" Pulley
URD 2.1"/Nose cone replacement
URD SuperGrip Crankshaft Pulley
URD 7th Injector
URD AIC/FTC w AFR calibrator
TRD Dynamic Tensioner
Walbro 190LPH Fuel Pump
170F T-stat
Denso IK22 Plugs/Wires
Moroso air and oil separator 85651

Air intake & exhaust:
Deckplate mod
Intake Silencer Removal
Wotefusi Snorkel w YodaTeq Grill
Airaid Modular Intake tube
Doug Thorley Headers
MagnaFlow 51006 Hi Flow Cat
Borla 14659 Cat-Back Exhaust
OEM Front O2 sensor replacement
Exhaust Pipe SAWZALL Chop

Electrical system:
Optima Yellow Top battery w/ military terminals
“Big 4” wiring upgrade (Marion Bumper 2 Bumper)
250A alternator powder coated red
Warn Power Interrupt Kit for winch
Fulltime 12V power mod for accessory outlets
Accessory Fuse Block install
-4Ripcord Acc Fuse Block mount
-Blue Sea 5025 ST Blade Fuse Block (6 circuit)
-Blue Sea 5026 ST Blade Fuse Block (12 circuit)
-100A relay (ACC triggered)
-Blue Sea 285Series Surface Mount 100A Circuit Breaker
-4ga welding wire/marine grade tinned copper lugs
-Anderson SB50 ARB/Engel Fridge 2-PIN to Battery Complete Wiring Kit (10ga) for cargo area
-Rear Power Panel Install
-J.A.'s Fog Light Mod
-J.A.'s Constant 12V power outlet mod

Transmission/clutch:
Original OEM 1999 R150F 5 speed-Full rebuild with R452 mod 3/2023
URD Short Throw Shifter
Marlin Crawler HD shifter seat & socket
Marlin Crawler HD flywheel (23.2lb) w HD pressure plate bolt kit
Marlin Crawler 1200lb clutch (Seco Disk/Aisin Cover)
New OEM Clutch Master Cylinder
New OEM Clutch Slave Cylinder
Redline MT-90 Fluid

Drivetrain:
“Blue-wire” mod (allows E-locker engagement in 2Hi/4HI)
ECGS Nitro 4:88 w ARB locker up front
ECGS Nitro 4:88 R Ring & Pinion diff (factory e-locker in rear)
Lucas 85W140 Non-synthetic gear oil F/R diffs
Dual Case setup with OEM Chain Driven rear TC (2.57) and Marlin Crawler Gear Driven front "TacoBox" (4.7) w/clockable Inchworm adapters
RADesigns Triple Sticks
OEM Rear E-locker

Steering:
Original OEM steering rack
New OEM ITREs, OEM Driver OTRE, NAPA Passenger OTRE
Energy Suspension Bushings from Wheeler's Offroad

Suspension & Chassis:
Front:
SPC Light Racing UCAs
Radflo 2.5in/650lb COs
Strongflex Bushings in LCAs
Wheeler's Front SuperBump Bumpstop set
OEM LBJs
Total Chaos Spindle Gussets
Aisin Manual Hubs
Lotus axles
Addco 573 sway bar w/Energy Suspension greasable poly bushings, Green Grease (removed)
Toytec 1” Diff Drop

Rear:
OME 861 coils
Radflo 2.5 remote resi shocks
Tokico Black Heavy Duty Shocks 48531-69417
SS Adjustable Panhard Bar
SS Extended bump stops/Daystar bump stops
Strongflex bushing in rear upper control arms
SS rear lower control arm replacement
Extended Rear Differential Breather
Addco 483 sway bar w/Energy Suspension greasable poly bushings, Green Grease
Eimkeith Panhard Correction Kit Install
Replaced rear axle bearings/seals with OEM parts

Misc:
SS Rear Polyurethane Body Mounts
Toytec 1” Body Lift
MStudt extended sway bar double disconnect links rear
Yota driver-side lean correction:
-Toytec TP14 (1/4”) driver front spacer
-OME 80PF10 (10mm) rear driver spacer

Wheels, Tires, Brakes:
16 x 7.5” FJ Cruiser Black Trail Edition Wheels, 15mm Offset
285/75R16 BFG All-Terrain T/A KO2
Spidertrax wheel spacers 1.5/1.25"
SCS F5's 16x8, 3.5in BS
285/75R16 BFG Mud-Terrain T/A KM3
Wheelers Off-Road SS Extended Brake Lines x3
NAPA Eclipse 13WL calipers (TBU)
OEM rotors/pads

Armor:
Shrockworks front bumper w/stinger
CBI rear plate bumper w/ dual swingouts and dual jerry can holder
Shrockworks full skids
Stubbs Welding HD-SKO Sliders
TaterFab Slider Top Plates
Lotus RCAM Skids
BudBuilt rear diff skid

Additional Instrumentation:
Lotek A-Pillar Dual Gauge Pod (Color Matched)
PLX DM-6/SM-AFR
White TRD Boost Gauge
ScanGauge 2 OBDII Interface
Hilux Surf Field Monitor

Exterior Lighting Upgrades:
LS460r Bixenon projector retrofit
-D2S: Morimoto 5Five DSP ballasts
-MotoControl Bixenon: H4/9003 harness
-Osram Xenarc 66240 CBI bulbs
-Morimoto XB LED 100mm white angel eyes
Rigid Industries 91061 SR-Series White 10” Driving LED Light Bar in Hood Scoop
Rigid Industries 93551 SRQ2 Flush Mount Pair in rear bumper
Rigid Industries 50211 D2 Wide on CBI ditch light brackets
VLED 5.5K 194 WHITE HIGH OUTPUT 360° 26 LEDs front corners
VLED 921 5K White (500 lumen) back up LEDs
VLED 5.5K WHITE AMBER SWITCHBACK 70 LED TURN SIGNAL BULBS 1157 2057 (Front bumper turns)
VLED HIGH VISIBILITY RED 6 LED 7443 7440 (taillights/brake lights)
VLED HIGH VISIBILITY RED HIGH POWER 6 LED 921 (3rd brake light)
VLED HIGH VISIBILITY AMBER 6 LED 7443 7440 (tail turn lights)
VLED VLR-6 PRO SAFE LOAD TURN SIGNAL RESISTOR EQUALIZER-6 ohm x4 (each turn signal)
VLED VLR-25 PRO PARKING LIGHT RESISTOR-25 ohm x1 for 3rd brake light to get rid of ABS light
PIAA 580s converted to 55W HIDs (DDM Tuning Ultra Kit with 5500K bulbs) on Bumper
PIAA LP530 Fog lights w/mod to stay on when high beams are on
Clear Corner (JDM) / Clear turn Lenses (Ebay Version)
’01-’02 Tail light swap/lightly smoked
Lux lighting rock lights x8
Headlight Filler Panel LED bars-Rigid Industries 906213BLK

Interior Upgrades:
LED swap Dome/Speedo/Console lights
LEDGlow Lighting Courtesy floor lights (door triggered)
Custom Wet Okole seat covers (black, red piping, TRD logo)
WeatherTech Digital Fit Floor Liners & Cargo Liner w TRD decals
Moved Driver's Side Grab Handle to above door
Top tether bracket/ child restraint system (removed, no longer needed)
OTRATTW custom switches
Additional switches added on armrest
Additional switches added to radio bezel
JZiggy Panavise/Ram mount setup
Victory 4x4 Door Molle Panels
Victory 4x4 Console Molle Panels
Rear Hatch Window Switch Mod
Rago Fab Molle Panels
Raingler Attic (removed)
Center console rear ashtray conversion to Blue Sea 4.8A dual USB plug
Dorman seat heater install removed

Exterior Mods:
Custom Billet grill
Gobi rear ladder
Whitson Metal Works Full length Roof Rack with Sunroof insert/custom fairing
Front Runner Roof Rack & Pro Table & Fishing Rod Carrier
Added OEM rear wind deflector
Line-X premium: grill, hood lip, roof rack, fender flares, quarter panels, rear wind deflector, sliders, ladder
Front Window/Rear Window/Hatch/Windshield eyebrow tint
Flare edge trim
WeatherTech Side Window Deflectors-In-Window-Channel x4
CBI ditch light brackets
Insain Fab 3rd Gen CB antenna mount (modded to fit with CBI rear bumper)
Rad Rubber Designs Engine Splash guards (1" BL)
Overlook Graphics Flag Decal, Matte Black
Marcus Clarkus End Cap install

Stereo & Coms Upgrades:
Uniden Pro520XL CB Radio (installed in the ashtray location)
Pyle PSP8 5in PA speaker (installed in radiator skid plate)
Yaesu FT-60R handheld Ham Radio
Diamond MR77SMA 144/140 Mobile Mag Antenna
Firestik II 4ft CB Antenna w/Tuned Tip
Vibration/Sound deadener treatment
Kenwood Excelon DDX9905S stereo
Kenwood CMOS-230 backup camera
JL Audio XD700/5 amplifier
Hertz speakers ESK 6.5 w crossover (front) / ECX 5.25 (rear)
JL Audio 10TW3-D4 Subwoofer (custom install in right rear cargo wall) by Custom Sounds, San Antonio
“Y” adapter for front/rear antenna plugs
Added power antenna up/down switch

Camping/Recovery gear:
Custom Camp Table/Tilting Fridge Storage System
ARB 50qt Fridge/Freezer
Alu-Cab Tilting Fridge/Freezer Slide
Tepui 6’ Awning mounted to roof rack with ARB OS850 awning mounts
Bush Company 270XT Max awning
ARB CKMA12 Air compressor mounted in engine bay on custom Tater Fab battery box
ViAIR 450P Portable Air compressor
Warn M8000 winch w/synthetic rope & wireless remote (pending install)
Factor 55 ProLink
High-Lift Jack on rear bumper
20L fuel can on rear bumper
Bag of stuff: jumper cables, battery jump start kit, straps, winch accessories, shackles, tools, etc.

Other:
AJT Design Injection Key Fob
High Pressure StrongArm struts for rear hatch

[papabeach]

So it has finally begun...years of trolling T4R...I finally have my own thread. I recently did a ton of maintenance as well as suspension/steering rebuild and thought this was as good of time as any to get this going...

Pics and comments of rebuild to follow...


*New SPC LR UCA, Radflo 2.5in/650lb COs, Strongflex bushing in LCAs


*Fought with this one for too long...eventually met Mr. Sawzall and all was right in the world of dealing with rusted cam sleeves


*Problem solver for rusted cam sleeves...


*No air chisel available...did this one on my own and took the other side to the shop at the end up my street for some air chisel action


*cleaned up, wire wheeled, rust inhibitor, VHT enamel paint and new bushings

[papabeach]

Steering Rack Bushing Install (Energy Suspension) went well...but don't use the small sleeve for the top bolt...you will find out quickly it doesn't fit...lessons learned at 1am under your 4Runner...doh

A big shout out to Sean and Timmy the Toolman for the excellent how-to videos. Their instructions were great...I rented my press and adapters from O'Reilly's.

[StreetCreeper]

Great looking truck! Looks almost too good like it's a toy. Makes me want to go play with my kids Tonka trucks!

Sorry couldn't resist...

[papabeach]

*Not perfect but pretty good, caster set in the recommended neutral position
*I now have some wheel well rubbing that is new I need to look into but for now I am enjoying a brand new ride...will put some road miles on it, make sure nothing shifts and then see about some trail trials...
*If anyone has any alignment thoughts I am happy to hear them

[infamousRNR]

This thing is a BEAST! Loving it PAPA, I'm
Glad you finally got around to puting together this build thread for the rest of us to enjoy!

[papabeach]

* Had to drop the rear driveshaft to get the right angle to get this fitting in...PITA. And I have no idea if anyone can actually fit a torque wrench on the front of the rear driveshaft nuts...I just put a wrench on them and tightened by hand


*Drivers side plugs on right...lots of threads about known uneven wear pattern...this was a bit of a surprise to me as I had recently asked the mechanic that works for me when I don't have time and/or am over my head to check the plugs and he said they were fine...

[papabeach]

*I actually broke the bottle jack trying to get this bushing out. Outer sleeve was seized to the arm so I melted the rubber, cut the cap off the metal sleeve and inner sleeve/residual rubber dropped out and I chiseled the sleeve out (see earlier post). I even tried the bottle jack from my 97 LC...this thing was not coming out without a chisel!


*Side by side comparison of OEM rear LCAs with approx 200K mi on them and the aftermarket ones sold by Steve and Sonoran Steel...very easy swap though did have to use a ratchet strap to get the bolt holes lined up.


*This is not what a healthy upper ball joint should look like...was shocked to see this...glad I upgraded to the SPC arms


*The unecessary cleaning/painting of the Rear Upper control arms followed by Strongflex bushing install

[Unner]

Glad to see you finally got a thread up here!

[papabeach]

Originally Posted by Unner

Glad to see you finally got a thread up here!

Better late than never :-)

[papabeach]

Nice Toyota meet at Gandy Beach today! We brought our 3rd gen and 80 series. It was nice to finally have the chance to meet some local enthusiasts and get some more ideas....when I got home I pulled the trigger on a Hobart 140...gonna have to get some practice then some "enhancements" will be short to follow.





Not the nicest beach in the world but there aren't many you can drive on and this was 15min from my house...PERFECT!

[papabeach]

Back to Firestone for post SPC LR UCA install alignment for 2nd time. First tech didn’t bother with any of the additional adjustments (caster plates still at “D” and upper camber bolts in the middle where I left them post install). Tech had front cams all the way out, rear cams all the way in.

Today: different tech who was happy for me to help. Fwe started with front cams all the way in, rear all the way out and caster plates on “G” and camber bolts all the way in. Some minor tweaking of the cams and the had to push the tie rods ends out on both sides to finish. He left the caster 0.5 degrees low on the drivers side to compensate for road camber.

Now I have no rubbing, track straight, still returns to center following turns, requires little if any steering adjustment when going straight. Only complaint is a little slop (less responsive) in steering wheel when going straight but not significant and I doubt I would have noticed if it weren’t for my recent education and extra time on the alignment rack.

Have a trail ride planned in a few weeks...will see how it does then.

On a side note it looks like my rear diff isn’t centered but I am not sure if it is worth adjusting the track bar to adjust. Anybody have any thoughts?

[papabeach]

Finally replaced broken Fob...nice upgrade. Thanks to @infamousRNR for the recent post that these were available.

[Chim]

Nice, I bought a key fob case too because of his post I got the blue screws.

[gamefreakgc]

Have you thought about installing the TransGo valve body shift kit? It's the "valve body upgrade" that gets thrown about on here that's a "must have or you'll cook your transmission" (which isn't true).

But it really cleans up the first gear shift. Not sure how it'd affect crawling though...