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Old 01-05-2022, 05:19 PM #1
Bad Luck Bad Luck is offline
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Bad Luck's Boring Build Biography

I didn't do this with my first 4Runner, but figured I might as well start one for my newest addition. I purchased this one with a grenaded transfer case, destroyed driveshafts, and mangled exhaust from a gentleman in Columbia, TN about an hour south of Nashville, TN. What Google Maps claimed was a 6 hour trip each way turned into closer to 8 hours each way between stopping for gas/food/bathroom and being stuck in construction traffic on I-40. 400 miles each way with a truck pulling a car hauler and a bored girlfriend makes for a long day. We left at 8 am on November 6th and didn't get home until 2 am.

This new 4Runner was in really good condition minus the obvious mechanical problems and a few minor dents/dings and carpet stains. Best of all it came with a thick file folder of receipts dating almost back to it's first oil change! I originally wasn't a huge fan of the color (Desert Dune Metallic) but it's growing on me and it still has all it's clear coat unlike my green one lol!

I dropped it off at work and then spent the next month and a half gathering parts. I wasn't able to find OEM manual driveshafts so I ordered some from 4xshaft using some measurements from Team_Jake since I didn't have a transfer case to measure from. I originally was going to get a transfer case from a guy parting out 4Runner's in Little Rock area but I got tired of waiting/postpones/lack of communication and ended up ordered one from LKQ posted on eBay. Strangely enough it was cheaper to buy it off eBay than to buy it directly from LKQ.

Twas the week before Christmas and my girlfriend was out of town which left me for extra time to spend after work fixing her up. What was left of the old transfer case was easily removed (there wasn't much still attached to the transmission) and a used j-shift with allegedly 131k miles was installed along with new driveshafts. I had to transfer the transfer case shift lever from the old transfer case to the new one since the vehicle is a manual. While I had it in the shop and work was slow I changed front/rear diff fluid, transmission gear oil, cleaned/flushed power steering, and engine oil and filter. The timing belt looked in good condition, but the valve covers/half moons were definitely leaking. The radiator could probably use replacing which will probably happen when I flush the cooling system of the green coolant that's currently in it.

The mechanics that looked at it had warned the previous owner that the transmission output might have been damaged with the transfer case destruction, but I didn't think that was very likely in my opinion. Luckily for me I was correct. She runs and drives, but obnoxiously loudly due to the exhaust breaking off after the first catalytic converter (California emissions). I paid a work friend $40 a few days later to weld it up at work best he could, and itís so much quieter!

I transferred my ultraguage/mount and bluetooth radio over to my new 4Runner. I still need to figure out what to put in my ultragauge in place of transmission temperature. Iíve got a few lights that are burned out on the dash that I need to fix. I tried putting new bulbs in the hvac controls, but the green covers tore. I also broke the ac button in the process. So bulbs (90010-05152 X2) and an ac switch (84660-35030) are ordered. I didnít think the bulbs would be a big deal or noticeable, but I was wrong. I replaced the transmission shift knob with an all rubber one (33504-20100-C0) and infilled the shift pattern and numbers on it and the transfer case shift knob. I honestly wish I would have spent the extra $20 and got the exact replacement (33504-20120-C0) but maybe it will grow on me.

I also installed the Spiker Engineering dash car mount and put my Spotify Car Thing on it. So far I have no complaints, but I havenít really been driving this 4Runner much as I still havenít registered or insured it.

Overall I couldnít be happier with my new to me 4Runner. Iíll attach some photos of the carnage below lol
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Bad Luck's Boring Build Biography-image5-jpeg  Bad Luck's Boring Build Biography-image1-jpeg  Bad Luck's Boring Build Biography-image2-jpeg  Bad Luck's Boring Build Biography-image4-jpeg  Bad Luck's Boring Build Biography-image3-jpeg 
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Old 01-05-2022, 05:19 PM #2
Bad Luck Bad Luck is offline
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Bad Luck Bad Luck is offline
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2000 4Runner SR5 V6 Manual 4WD

MAINTENANCE

Purchased November 5, 2021 at 199753 miles


12/20/2021 199753 miles
-Replaced transfer case w/LKQ used unit w/133k miles $297.73
-New front and rear driveshafts from 4xshafts.com $834
-Belt tensioner stud (44469-35010), belt tensioner bolt (90119-08A31), belt tensioner nut (90179-10209) ~$13
-Cleaned power steering reservoir, flushed power steering w/Dexron VI, and replaced power steering o-ring (90301-11016) ~$3
-Drain/fill rear differential w/Mobil 80W-90 $FREE
-Drain/fill transfer case w/Mobil 80W-90 $FREE
-Drain/fill front differential w/Mobil 80W-90 $FREE
-Replaced front differential drain plug (90341-24016) and fill plug (90341-18060) ~$22
-Changed oil and filter w/5 quarts Dexos full synthetic 5W-30 and 1 quart Dexron VI and OEM filter (90915-YZZD1) ~$5
-Inspected timing belt (looks good/no cracks)
-Inspected front and rear brakes (looks good)
-Inspected rear axle seals (right rear axle seal leaking)
-Inspected radiator and coolant (radiator brown but not cracking/coolant is green)
-Inspected for oil leaks (valve covers/half moons leaking)

12/23/2021 199841 miles
-Swapped factory radio for aftermarket bluetooth radio $FREE
-Transferred ultragauge and mount $FREE
-Installed dash phone mount and Spotify Car Thing. $50 mount and $80 Spotify Car Thing
-Replaced transmission shift knob (33504-20100-C0) $50 (infilled the shift pattern/numbers with white nail polish)
-Infilled transfer case shift knob with white nail polish to match transmission shift knob $FREE
-Welded up stock exhaust $40
-Flushed clutch fluid $FREE
-Flushed brake fluid $FREE
-Drain/fill transmission w/Mobil 80W-90 $FREE
-Swapped wheels/tires $FREE

1/17/2022 200202 miles
-Fixed rear oxygen sensor connector/wiring $25
-Cleaned off transmission/transfer case more. Possible leak at transfer case/transmission mating area (transmission output seal?). Possible crack in the transmission and leaking driver side of transmission below the shifter base.
-Inspected engine for leaks. Valve covers/half moons/cam seals leaking. Probable rear main seal leak. Possibly oil pan leak as well. Added uv engine oil dye.
-Drained transmission fluid and refilled with Redline MT-90 $75/gal
-Replaced both lower ball joints and lower ball joint bolts $250
-Adjusted toe and melted right inner tie rod boot/bellow $FREE
-Removed factory step rails and relocated to dumpster $FREE
-Installed BH3D printing front SR5 mudflaps $80 1996-2002 SR5 4runner Mud Flap End Caps | Etsy

1/19/2022 200252 miles
-Installed Spiker Engineering hood struts $93
-Replaced spark plugs (90919-01192 $16), spark plug wires (Denso 671-6182 $30), and ignition coil boots (Denso 671-6248 $50) $96 Total
-Replaced pcv valve (12204-62010) and pcv valve grommet (90480-18001) $17

2/19/2022 201314 miles
-Removed Yakima roof rack rails (had to buy a replacement key to unlock it $35)
-Installed some OEM roof rack delete rails and cleaned the dirt/debris off the top. Added some silicone around the holes/threads for the roof rack rail fasteners. OEM roof rack delete rails $40 and silicone $10.
-Replaced the melted passenger inner tie rod boot that I melted last alignment. Set toe again. Moog K100183 $15
-Ordered/cut 2 replacement keys from Toyota dealership next door. 90999-00185 $15
-Replaced defrost 90010-01041 $5 and rear window 90010-01042 $5 bulbs. Replaced HVAC unit bulbs 90010-05152 $20. The off brand ac switch I bought does not want to go on there at all. I think I'll have to order OEM for that.

3/9/2022 201707 miles
-Replaced left front fender with one from a junkyard in central Oklahoma $90
-Removed clutch pedal assembly, removed weird coil spring, replaced bushings (90386-13007 x2), reinstalled clutch pedal assembly and installed linear spring (90507-14030) $12
-Replaced AC button (84660-35030) $50

3/21/2022 201941 miles
-Fixed exhaust leak and installed turn down after muffler $50

4/3/2022 202217 miles
-Replaced rear carrier bearings (90366-50007) $120
-Fresh rear diff fluid $FREE

5/13/2022 202867 miles
-Removed old floormats, vacuumed floormats/carpet, and install Weathertech floormats front and rear. $217
-Replaced worn ignition cylinder with new ignition cylinder coded by local locksmith. $50 recode ignition cylinder. Ignition cylinder 69057-35070 and 4 blank keys 90999-00185 $95
-Modified old key to only work in door locks and not ignition. $FREE


MAINTENANCE/MODS TO DO
-Replace valve cover gaskets/half moons
-Replace filler cap gasket
-Replace radiator/flush cooling system
-Replace rear axle seal and wheel bearings
-Replace front pads/rotors
-Install rear rotor kit
-Rear main seal/flywheel/clutch/transmission
-Install relays to retain radio power while starting engine
-New exhaust (Walker 52399, Walker 16535, and Magnaflow 19538)
-Underhood lighting?
-Interior ambient lighting?
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Last edited by Bad Luck; 05-13-2022 at 05:31 PM.
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Old 01-05-2022, 05:19 PM #3
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Old 01-05-2022, 05:58 PM #4
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Nice.. I have one Just like it same color [1998] but a auto. Glad you started your own build thread so you can show me the clean chassis.

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Old 01-05-2022, 06:00 PM #5
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Toyota and Subaru use the same gear shift stick thread diameter/pitch... I run a nice WRX shift knob on my Camry. Worth a look if you want something newer/nice looking and OEM quality.



Desert Dune just disappears as a color. Can be good or bad. I would have preferred Millennium Silver on mine, but it wasn't available in '99 anyway...

-Charlie
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Old 01-05-2022, 06:21 PM #6
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Quote:
Originally Posted by brillo_76 View Post
Nice.. I have one Just like it same color [1998] but a auto. Glad you started your own build thread so you can show me the clean chassis.

Sent from my SM-A505U using Tapatalk
It's a surprisingly clean frame for it living a good portion of it's life around St Louis, MO and some of it's life around Chesapeake Bay, VA. I was expecting some flake rust on the frame but it's only got a little bit of surface rust on some of the welds and the rear axle housing.

Quote:
Originally Posted by phattyduck View Post
Toyota and Subaru use the same gear shift stick thread diameter/pitch... I run a nice WRX shift knob on my Camry. Worth a look if you want something newer/nice looking and OEM quality.



Desert Dune just disappears as a color. Can be good or bad. I would have preferred Millennium Silver on mine, but it wasn't available in '99 anyway...

-Charlie
That's good to know. Opens my options up for shift knobs. Aftermarket ones just look and feel so cheap. Desert Dune just doesn't know if it wants to be silver or tan in my opinion. It's not a bad color, but it's not a great color either lol
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Old 01-05-2022, 06:26 PM #7
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Nice, Love the Desert Dune Metallic. I had a 97 5 spd I paid $4,700 for in 2013, Sold the thing like an idiot with 300k for $5,500. It ended up in Olympia WA and haven't seen it since.
Couldn't stand not having a 3rd gen so I picked up the Sport for $4,300. It mowed down a deer and was trashed. I overpaid, but that is how the market is in MT.

The color hides the dirt well. Congrats. Look forward to the build.
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Old 01-05-2022, 06:53 PM #8
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Great start. subscribed.
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Old 01-05-2022, 07:35 PM #9
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Desert Dune just doesn't know if it wants to be silver or tan
ďGreigeĒ

But seriously, awesome find. Looking forward to your posts!
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Old 01-06-2022, 09:56 AM #10
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Anxious to follow this along and see the progress as you catch up on the maintenance.
Donít forget to include more pics!
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Old 01-18-2022, 10:14 AM #11
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1/17/2022 200202 miles
-Fixed rear oxygen sensor connector/wiring $25
-Cleaned off transmission/transfer case more. Possible leak at transfer case/transmission mating area (transmission output seal?). Possible crack in the transmission and leaking driver side of transmission below the shifter base.
-Inspected engine for leaks. Valve covers/half moons/cam seals leaking. Probable rear main seal leak. Possibly oil pan leak as well. Added uv engine oil dye.
-Drained transmission fluid and refilled with Redline MT-90 $75/gal
-Replaced both lower ball joints and lower ball joint bolts $250
-Adjusted toe and melted right inner tie rod boot/bellow

I had to break out the hot wrench (oxyacetylene torch) to get the tie rod lock nuts to loosen. I also had to heat the right inner tie rod in order to get it to adjust. I had the inner tie rod boot/bellow pulled back, but when I was putting the torch away the boot slipped back into place and proceeded to melt away I ordered a moog replacement (MOOG K100183).

EDIT- Forgot to add that I removed the OEM step rails and threw them away. Installed BH3D printed SR5 mudflap fillers. 1996-2002 SR5 4runner Mud Flap End Caps | Etsy
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Last edited by Bad Luck; 01-18-2022 at 12:34 PM.
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Old 01-18-2022, 03:35 PM #12
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Wow, no time being wasted here, lots done in short order, run Patrick run!!
Love Desert Dune on these Runners.
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Old 01-18-2022, 03:43 PM #13
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Originally Posted by Bad Luck View Post
melted right inner tie rod boot/bellow
When I first saw this line, I thought I was about to learn about some new and interesting mod!!
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Old 01-18-2022, 04:32 PM #14
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When I first saw this line, I thought I was about to learn about some new and interesting mod!!
Lol nope just my own stupidity! Now I guess I'll get to see how a moog boot holds up to heat
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Old 01-18-2022, 07:30 PM #15
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Originally Posted by Bad Luck View Post
Lol nope just my own stupidity! Now I guess I'll get to see how a moog boot holds up to heat
Mine melted as my buddy changed my inner tierod end for inspection one year. They got my cv boot too... This is one reason I quit using torches and went to plasma cutting..;-) I just put a Moog boot on the 1997 limited I am redoing. I am curious how they hold up in general. Let alone with melted metal being tossed at them..
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5 3rd gens listed in the build thread
Build Thread: https://www.toyota-4runner.org/3rd-g...os-builds.html
Brillo's Bucket Fluid Exchanger: https://www.toyota-4runner.org/3rd-g...ml#post3358086
Sparks Plugs Wire and Coil Information: https://www.toyota-4runner.org/3rd-g...on-5vz-fe.html
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