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Old 01-20-2020, 03:37 AM #1
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Swapping build to new 4runner questions.

So, my old 2002 4runner was totaled. It slid on snow and ice and flipped on the driver's side. I found a replacement 2002 SR5 in Millennium Silver, pretty much the exact vehicle minus a sunroof.

I am looking to swap my build over and have been trying to work out a sensible order in which to do things. Some are obvious, some are less so.

I know a few of you have embarked on the same type of build swap and I would appreciate any input.

The good news is that most of the mods survived. What makes this a bit touch and go, is that my new 4runner is still my DD. Also, I will be doing most of the work at some of my friend's garages.

At some point, what is left of my old vehicle will go to scrap after I strip it as much as I can. But I plan on swapping the entire rear axle (it has gears and locker) over to the new vehicle. Same with the front diff. Is there another good option besides putting the new 4runner's axle back on the old 4runner that would give it mobility enough to get hauled off?

The plan as I see it now:

Some changes

*I will be adding a 1"BL to make life a little easier. I will also be replacing all the old body mounts with new Energy Suspension body mounts.

*Rebuild front Kings with 650# springs and very little preload.

*Upgrade to Rokmen Trail Series Lower Links for 96-02 4Runner.

*Add eimkeith PCK to rear. PCK (Panhard Correction Kits) – eimkeith.com

*Add my TC spindle gussets that I have been sitting on for a few months.

Some Maintenance

*New LBJs

*New OTR

*New SPC UBJs

*New rear Tokico Black LC shocks.

*New Radiator looking at Koyo NEW ALUMINUM Koyo Radiator for 3rd Gen Toyota 4Runner - VH010665N

or just get another Denso from Taiwan.

*Eventually TB job once I get all the other crap sorted.

On to the swap

Some items should be too easy. They are the same year, so there shouldn't me much in the way of surprises in year of 4runner variations I have to deal with.

Easy direct swap parts:
*HID Headlights, Supertones horns, Trans radiator, Rear mounted ARB twin air compressor (whole rear interior cargo panel should be able to be discoed from air lines / power controller wiring and snapped into new vehicle.)

Meat and Potatoes portion of the swap. (cutting, welding, wrenching)

I have been trying to come up with a good order to do things that will try to keep the new vehicle from too much downtime and prevents me from having to go back and take things apart again.

*Sliders (can get cut off and rewelded in any order after BL is installed.

*Front bumper before suspension and tire/wheel swap. Some cutting, but I can't remember if I had welded front facing bolts out of endcaps for frame during my Shrockworks bumper install. So I am not sure about all might need to be welded on. I need to look at instructions.

*Big job: Swapping rear axle, installing new RLCAs, new RUCA bushings, PCK install, Front diff swap, might try to leave as much connected for swap as I can. (we'll see), delete factory cam tabs, add TC cam tabs, (not fun job), swap front and rear suspension, (Adding spindle gussets ahead of time when front shocks are getting rebuilt) Move TBU brakes and rotors over to new veh. Swap SPC UCAs.... *exhale*

Follow up to big job: Tub job, snorkel, add new 4X Innovations rear bumper for 1" BL, cross fingers and hope that tire carrier swing out goes on without drama, work on any electrical odds and ends / wire routing to get compressor and rear locker up and running.

It's A LOT to think about...

I am just trying to figure out a better solution after my old rig is missing its rear axle front suspension that doesn't involve having to lay it on the ground and drag it out of a friend's workshop.

The strip:

I am trying to figure out what all I want to strip from my old rig. It might be nice to have a spare tranny, interrior parts, (seats, surviving trim), door (well... passenger side anyway) to sell or to keep as back up should I need them in the future.
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Old 01-20-2020, 10:33 AM #2
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well, regarding the stripping and keeping section you detailed above, did you need any of those things for your first 4runner? how long have you gone without needing any of those items? IIWM, I would only keep the items you have needed to replace in the past.
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Old 01-20-2020, 01:48 PM #3
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I would keep as much stuff as i can from the old truck if space permits. My brake booster is making a hissing sound and trying to find a used oem in decent condition. Are you going to sell the motor' trans, transfer case etc as a whole? If not strip it for all the useable parts. like electonic sensors, cam sensors, knock sensors etc also fuel injectors maf sensor charcoal canister, oil pump etc I have over 400k on my runner and am seriously thinking of buying a 3rd Gen that's being parted out in decent shape and stripping it because with all the miles I have I will need the parts going forward. Hell a new oem brake booster is like $1150 from the dealer. Great find looking forward to your new build. Good luck.
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Old 01-20-2020, 01:56 PM #4
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if it were me and this was possible, i would keep as much as you can.
Again, some may not agree, but i would try to hold onto the drivetrain, diffs, axles, etc. just knowing you could use them eventually or hell even resell if you didnt. Never hurts to have a spare 5VZ and trans assuming everything is alright with both or maybe its an opportunity to rebuild. This also depends on your ability to store all of this.

Knowing you dont want to leave it sitting on the frame, maybe put it down on dollies or something where you can roll it out for a wrecker to haul it off? My dad and I used some 4x4s and casters to build 4 frame dollies once, that way we could roll a body out to the street.
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Old 01-20-2020, 03:10 PM #5
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Knowing you dont want to leave it sitting on the frame, maybe put it down on dollies or something where you can roll it out for a wrecker to haul it off? My dad and I used some 4x4s and casters to build 4 frame dollies once, that way we could roll a body out to the street.
I was able to get most of a unibody chassis into a utility trailer with an engine hoist and some ingenuity... It'll get lifted off the trailer by a forklift if you drop it off at the recycling yard yourself.



I did use a car trailer and made/kept my parts 4Runner a roller for that project though...

As for parts - take off as much stuff as you think you can sell and sell it. Keep the stuff you are pretty sure you are going to need in the future, sell the rest. Otherwise, it'll just take up space in the garage (ask me how I know...).

-Charlie
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Old 01-20-2020, 11:39 PM #6
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Thanks for the advise for far guys. I feel like I am trying to perform about a 5 year build in a couple weekends. It would be a helluva lot easier if I simply had a second vehicle. That way I could take my time and feel better about Humpty Dumpty in a million little pieces for a few days or a week at a time.

As far as keeping parts goes.. I think I will see what I can get for some of these parts. as a package. My engine and trans were fine before the accident. I just think that unless I get a certain number in my head for the parts, I might as well hold on to them. For instance.. If my trans were to go out in a year or two, I would be looking at possibly paying over $1,000 to get a new one, vs. having one on stand-by to swap in as needed. Engine was good, just had TB / WP belts, PCV valve done. So with either of these items, I could sell and use the money now, or hold onto them in case something came up.

I think I might be able to have a BIG JOB day, but leave out the tub job and snorkel for another time. So it would just be a lot of work on the front end; TC cam tab gussets, swap lower control arms (I just put in fresh White Line bushings in the old LCAs), UCA swap with new SPC UBJs, Spindle / TBU brake swap, New OTR, New LBJs, Swap rear axle, PCK, rear lift, and done... Easy.. Hahahaha... I might have enough people to do work on front and rear at the same time.
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Old 01-21-2020, 04:06 PM #7
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Do you have room for a 3rd vehicle/car? What about a $1000-2000 beater for a few months to take the risk away during the process? Sell it at the end of the swapover?

-Charlie
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Old 01-21-2020, 06:13 PM #8
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Quote:
Originally Posted by Road Bull View Post
I think I might be able to have a BIG JOB day, but leave out the tub job and snorkel for another time. So it would just be a lot of work on the front end; TC cam tab gussets, swap lower control arms (I just put in fresh White Line bushings in the old LCAs), UCA swap with new SPC UBJs, Spindle / TBU brake swap, New OTR, New LBJs, Swap rear axle, PCK, rear lift, and done... Easy.. Hahahaha... I might have enough people to do work on front and rear at the same time.
Sounds like a beast of a weekend, but at least you are swapping parts outright so you can just unbolt it all and get to it. An extra set or two of hands and you should be fine. And you could push the PCK back if time gets tight.

The only thing I don't see on your list is poly bushings for the steering rack since it will be unbolted for the cam tab gussets. Do you have an air chisel to remove the OEM cam tabs? Can't remember if you had the gussets on your other truck.
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Old 01-21-2020, 07:25 PM #9
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Sounds like a beast of a weekend, but at least you are swapping parts outright so you can just unbolt it all and get to it. An extra set or two of hands and you should be fine. And you could push the PCK back if time gets tight.

The only thing I don't see on your list is poly bushings for the steering rack since it will be unbolted for the cam tab gussets. Do you have an air chisel to remove the OEM cam tabs? Can't remember if you had the gussets on your other truck.
Yeah, it's a lot of work. And yeah, the PCK doesn't have to happen at the same time. But doing the cam tabs while I have the LCAs out makes sense to me. I DO have new poly bushings sitting around, now that you mention it. Thanks fir the reminder.

If I don't have an air chisel, I think I will have to acquire one. The rears were a friggin bear the first time I did it. So the cam tab gussets are the main welding job priority. The other stuff, even the tub job can wait. With my old alignment, I wasn't rubbing lock to lock. And with 1" of BL, I should have even more clearance.
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Old 01-21-2020, 09:14 PM #10
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Quote:
Originally Posted by phattyduck View Post
Do you have room for a 3rd vehicle/car? What about a $1000-2000 beater for a few months to take the risk away during the process? Sell it at the end of the swapover?

-Charlie

This is the best advice in the thread so far.

Ryder, having a cheap ass DD for a few months will take so much pressure off of what you're trying to do. Just get a beater and sell it down the line.

As far as the Rockman links go, I'd just do what I did and get Metal Techs. You might have to call them as they aren't listed on the site but there 3rd gen lower links are bomb proof. They are also adjustable which helps if you care about pinion angle at all.

The PCK is super easy and 2 hours tops. Spindle gussets could be done at the same time. Body lift should be pretty straight forward. The rest of it you already know.

Remember, many hands make light work. IE, call ALL your buddies. Get both rigs close to each other and start swapping.

Wishing you an easy and trouble free swap.
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Old 01-21-2020, 09:50 PM #11
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For me personally, I would never let a group of people work on my vehicle at any given time but I do not ever trust anyone working on my vehicles LOL. You have an extra vehicle, its just totaled (this is sarcasm but bear with me). You're an experienced guy and obviously you've installed these mods in the past so you know your way around the individual jobs already, and you know what you would and wouldn't do in certain situations as well. Any of these jobs can be completed in one day, most can be completed with 1 - 4 hours depending on your tools. Just segment your workload, actually schedule out and plan exactly what is being done and on what date, what tools will be needed, supplies, torque specs, etc.

In addition to this, think about what sort of age-proofing you want to do before installing these parts. Having the rear end off of your rig can be extremely handy if you're looking to paint all of the nooks and crannies above the axle, maybe you want to apply some POR-15 on the top of the rear shock mounts to prevent settling dirt and rust occurring in the future. In this situation I know I personally could spend an entire day off of work perfecting the fine details, ensuring everything in that specific region was up to my standards and finally installing the rear end from the original runner, in an easy manner. If you plan on having this vehicle for life like I do with my 3rd gen and i'm only 24, then take your time and study exactly what you have by breaking these down into all separate jobs.

You might find when doing this that you will actually want to add in additional mods, or just new OEM parts, because it makes total sense at that point. If you have 6 people working on your truck in a shop things get slapped together in an afternoon or two, next thing you know something goes wrong and some ding bat is at fault but you have a way bigger project on your hands and your DD is out of commission.

A used truck is a used truck, a used toyota truck means we all love it and the things guaranteed to run. It doesnt mean anyone ever took care of any of the small things that needed attention over the years.

P.S. this is a badass thread. I applaud you for doing what I would have done and bought another 3rd gen. I am glad you were okay in the accident. I live in Michigan and I know winter weather can get sketchy very quickly. When I saw the picture of the new Runner parked in front of the original with the tarp / vehicle cover on it i started cracking up thinking "damn, that little silver thing doesnt even know what its in for" LOL!
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Old 01-22-2020, 11:46 PM #12
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Originally Posted by phattyduck View Post
Do you have room for a 3rd vehicle/car? What about a $1000-2000 beater for a few months to take the risk away during the process? Sell it at the end of the swapover?

-Charlie
I have been looking into this. Ideally, I would like to end up with a Tacoma as my second vehicle. Not sure I can swing it at the time, but I will be putting forth some effort this year to getting a second vehicle. It makes wheeling a and wrenching a bit less stressful having a secondary vehicle to rely upon.

Quote:
Originally Posted by theesotericone View Post
This is the best advice in the thread so far.

Ryder, having a cheap ass DD for a few months will take so much pressure off of what you're trying to do. Just get a beater and sell it down the line.

As far as the Rockman links go, I'd just do what I did and get Metal Techs. You might have to call them as they aren't listed on the site but there 3rd gen lower links are bomb proof. They are also adjustable which helps if you care about pinion angle at all.

The PCK is super easy and 2 hours tops. Spindle gussets could be done at the same time. Body lift should be pretty straight forward. The rest of it you already know.

Remember, many hands make light work. IE, call ALL your buddies. Get both rigs close to each other and start swapping.

Wishing you an easy and trouble free swap.
Thanks man! Yeah, that second vehicle is sounding pretty nice actually. I'll start poking around. I have a good core group of wheeling friends that are down to pitch in and help get wrenches turning.

Quote:
Originally Posted by VernySanders View Post
For me personally, I would never let a group of people work on my vehicle at any given time but I do not ever trust anyone working on my vehicles LOL. You have an extra vehicle, its just totaled (this is sarcasm but bear with me). You're an experienced guy and obviously you've installed these mods in the past so you know your way around the individual jobs already, and you know what you would and wouldn't do in certain situations as well. Any of these jobs can be completed in one day, most can be completed with 1 - 4 hours depending on your tools. Just segment your workload, actually schedule out and plan exactly what is being done and on what date, what tools will be needed, supplies, torque specs, etc.

In addition to this, think about what sort of age-proofing you want to do before installing these parts. Having the rear end off of your rig can be extremely handy if you're looking to paint all of the nooks and crannies above the axle, maybe you want to apply some POR-15 on the top of the rear shock mounts to prevent settling dirt and rust occurring in the future. In this situation I know I personally could spend an entire day off of work perfecting the fine details, ensuring everything in that specific region was up to my standards and finally installing the rear end from the original runner, in an easy manner. If you plan on having this vehicle for life like I do with my 3rd gen and i'm only 24, then take your time and study exactly what you have by breaking these down into all separate jobs.

You might find when doing this that you will actually want to add in additional mods, or just new OEM parts, because it makes total sense at that point. If you have 6 people working on your truck in a shop things get slapped together in an afternoon or two, next thing you know something goes wrong and some ding bat is at fault but you have a way bigger project on your hands and your DD is out of commission.

A used truck is a used truck, a used toyota truck means we all love it and the things guaranteed to run. It doesnt mean anyone ever took care of any of the small things that needed attention over the years.

P.S. this is a badass thread. I applaud you for doing what I would have done and bought another 3rd gen. I am glad you were okay in the accident. I live in Michigan and I know winter weather can get sketchy very quickly. When I saw the picture of the new Runner parked in front of the original with the tarp / vehicle cover on it i started cracking up thinking "damn, that little silver thing doesnt even know what its in for" LOL!
Thanks man. This build / rebuild will be a mix of swapping over major components of my old build, as well as updating and upgrading a few other things. Like, I decided I wanted to do a 1" BL this go-around (hopefully assist stuffing my 315s on my 3.5" BS wheels into the rear wells). So I am taking this as an opportunity to update the body mounts to Energy Suspension Body Mount Bushings. New rear shocks, new RLCAs, new RUCA bushings, new, LBJ, OTRE, and so on... So I am trying to do the easy upgrades as I can.
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Old 01-23-2020, 11:59 AM #13
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Quote:
Originally Posted by Road Bull View Post
I have been looking into this. Ideally, I would like to end up with a Tacoma as my second vehicle. Not sure I can swing it at the time, but I will be putting forth some effort this year to getting a second vehicle. It makes wheeling a and wrenching a bit less stressful having a secondary vehicle to rely upon.



Thanks man! Yeah, that second vehicle is sounding pretty nice actually. I'll start poking around. I have a good core group of wheeling friends that are down to pitch in and help get wrenches turning.



Thanks man. This build / rebuild will be a mix of swapping over major components of my old build, as well as updating and upgrading a few other things. Like, I decided I wanted to do a 1" BL this go-around (hopefully assist stuffing my 315s on my 3.5" BS wheels into the rear wells). So I am taking this as an opportunity to update the body mounts to Energy Suspension Body Mount Bushings. New rear shocks, new RLCAs, new RUCA bushings, new, LBJ, OTRE, and so on... So I am trying to do the easy upgrades as I can.
I see!! I honestly wish I had a garage lift because that would change my life!!!! Haha are you doing aftermarket RLCAs? If so which manufacturer? Body mount bushings are something I personally wanted to do as well. I've thought about 1" body lift on my truck because my 33s are pretty beefy but I drive the dunes a lot and sometimes you cant help but to get in some sketchy situations out there where you're at quite a steep angle, possibly sideways so I want a low center of gravity. This spring I'm going to do any mods I need to do to where my 33s can tuck all the way with no rubbing at all.
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Old 01-23-2020, 12:40 PM #14
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Join Date: May 2015
Location: Oregon
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I was in the same boat you are now. I would just take my time and swap what I can when I can. Nothing I did took more than a day at a time. And there was really no rush to hurry and bring the current runner to the level the old one was at unless maybe you have an event you are trying to attend. It goes way faster the second time :/
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4runner , front , rear , swap , vehicle

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