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 it’s 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. I’ve 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 didn’t 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 haven’t really been driving this 4Runner much as I still haven’t registered or insured it.

Overall I couldn’t be happier with my new to me 4Runner. I’ll attach some photos of the carnage below lol

Attached Images

         

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

5/20/2022 203149 miles
-Replaced front rotors (Bosch 50011224 $130) and front pads (Bosch BC611 $45) and new slide pins (Dorman HW14108 x2 $14)
-Replaced fuel filter 23300-62030 $60
-Changed engine oil $FREE
-Replaced oil fill cap gasket 90430-37140 $4

5/21/2022 203165 miles
-Flushed cooling system x3 with distilled water $10
-Replaced thermostat 9091603075 and thermostat gasket 1632562010 $32
-Replaced heater water valve 87240-35070 $35
-Replaced radiator Koyo VH010665N and radiator cap Koyo SK-C13 $420
-Filled cooling system with Toyota red coolant 00272-1LLAC and distilled water $70
-Removed and cleaned radiator overflow bottle $FREE

5/27/2022 203353 miles
-Replaced valve cover gaskets, spark plug tube seals, half moons, and cam plugs (Parts list in post #3) $146

6/4/2022 203456 miles
-Cleaned valve cover leaks with brake cleaner
-Removed skid plates to clean at a later time
-Drained engine oil, installed Fumoto F133N drain valve, filled engine oil w/syn 5W30 $28

7/16/2022 204488 miles
-Replaced upper and lower radiator hoses (16572-62090 16571-62070) and tension clamps (90467-37005 x4) $42
-Replaced shift knob with OEM leather knob (33504-20120-C0) $65
-Replaced fan clutch with Aisin FCT-013 $90
-Filled/purged engine cooling system with Toyota red coolant $FREE

7/30/2022 204747 miles
-Replaced air/fuel sensor (Denso 234-9003) $120
-Replaced MAF sensor (Denso 197-6020) $74
-Finally greased front and rear driveshafts (Lucas Red "N" Tacky #2) (McNaught k32 Grease Gun) $60

8/17/2022 205105 miles
-Replaced windshield through Safelite. Green with blue tint. $385
-Stripped nail polish from transfer case shift knob. Paint/polish had become sticky and runny in the heat.

9/15/2022 205606 miles
-Cerakote ceramic coated windshield $20
-Installed Hella 012010901 $22

11/5/2022 207064 miles
-Oil and OEM filter change $10
-Replaced spare tire valve stem and installed spare with valve stem facing down
-Tightened radiator drain plug
-Sanded thermostat housing hose connection where pitted with 150 grit

2/1/23-2/3/23 209278 miles

-Resealed oil pan $FREE
-Replaced front axle seals $40
-Replaced front axle shafts (TO-8043EXT) $250 RockAuto
-Replaced clutch/heavyweight flywheel/rear main seal (LCE Engineering Pro Clutch Kit) $837
-Replaced master cylinder $66
-Braided stainless steel clutch line $39
-Replaced transmission (slave cylinder/throwout bearing/arm included)
-5th gear swap on transmission $250
-Transfer case shifter gaskets $10
-Transfer case input seal $10
-Front sway bar bushings $FREE
-Front/rear brake lines and bled/flushed brake system(1st Gen Tacoma front hoses to eliminate hard line at calipers) $130
-Engine oil/gear oil/brake fluid $FREE

6/24/2023 213406 miles
-Replaced transmission with another new OEM transmission with original 5th gear ratio
-Applied QuikSteel to engine block crack while transmission was out

8/27/2023 215538 miles
-Replaced battery 24R O'Reilly's Extreme battery $218

12/15/2023 218458 miles
-Changed engine oil and filter $FREE

1/1/2024 218858 miles
-Rear axle seals, bearings, retainers $140
-Rear drums, shoes, hardware/springs $200
-Rear diff fluid $FREE

3/18/2024 219540 miles
-Replaced both catalytic converters and remaining exhaust/muffler with Magnaflow (93258, 93379, 19538) $1600
-Replaced downstream oxygen sensor with Denso 234-4153 $70
-Removed previous block crack attempt, cleaned block , and applied JBWeld high heat epoxy $30

8/8/2024 222256 miles
-Installed Satoshi grille and TEQ headlights/corner marker housings $840
-Changed engine oil $FREE
-Replaced front wiper arms/nuts/covers $100
-Installed missing door panel push pins $6


MAINTENANCE/MODS TO DO
-Replace rear axle seal and wheel bearings
-Install rear rotor kit
-Install relays to retain radio power while starting engine
-New exhaust (Walker 52399, Walker 16535, and Magnaflow 19538)
-Underhood lighting?
-Interior ambient lighting?

Parts Reference

NOTE: All part numbers listed below are for a 2000 Toyota 4Runner 3.4L MT/4WD unless otherwise noted. I highly recommend cross-referencing/verifying part numbers before ordering anything. Use at your own risk.


Transmission
R150F 33030-34100
Reverse light switch 84210-52050
R150F/A340F output seal 90311-40007
R150F overhaul gasket kit 04331-35250
A340F Transmission valve body gaskets 35433-60040 and 35434-60040
A340F Transmission pump seal 90311-38020
Dexron III compatible fluid 00718-ATF00


Transfer Case
Transfer case plugs (x1) (low range switch delete) 90341-18006
Transfer case input seal 90311-40021
Transfer case front output seal 90311-41012
Transfer case rear output seal 90311-41020
Shift lever oil deflector 36108-35060 (only comes with 1 gasket)
Shift lever oil deflector gasket (36345-35050)
Transfer case drain/fill plug seals 90430-A0003 (x2)


Engine/Engine Bay
Fuel filter 23300-62030
Air/Fuel Sensor 89467-35021 or Denso 234-9003
Denso Parts Finder: ERROR: The request could not be satisfied
Spark plugs 90919-01192
Spark plug wire set Denso 671-6182
Coil pack boot set Denso 671-6248
Negative battery post clamp 90972-06022
Positive battery post clamp 90982-05035
Power steering reservoir o ring 90301-11016
Alternator brush kit 27370-75060
Throttle position sensor 89452-35020
PCV hose 12262-62050
PCV 12204-62010
SS Rear Heater Pipes 87248-35061
Heater water valve assembly 87240-35070
Oil fill cap gasket 90430-37140
Thermostat 90916-03075
Thermostat Gasket 16325-62010
Radiator cap 16401-20353
Block Heater Kit C0140-02134
3.4L Vacuum diagram label 17792-62250
Oil Filter 90915-YZZD1 (standard size) or 90915-YZZD3 (larger size)
Upper Radiator Hose 16571-62070
Lower Radiator Hose 16572-62090
Upper/Lower Radiator Hose Clamps 90467-37005 (x2 per hose)
Fan Clutch 08921-04950 or FCT-013 (Aisin)
Cluster gauge coolant temperature sensor 82219-34020
ECM coolant temperature sensor 89422-35010


Valve Cover Gaskets/Seals
Valve cover gaskets 11213-62020 (x2)
Spark Plug Tube gaskets 11193-16010 (x6)
Intake Plenum Gaskets 17176-62040 (x2)
Washer Seals 90210-05007 (x16)
Camshaft Plugs 11188-62010 (x2)
Halfmoon Plugs 11183-62010 (x4)
PCV Valve Grommet 90480-18001 (x1)
Toyota FIPG seal packing 00295-00103 (x1)


Interior
AC Button 84660-35030
Clutch pedal bushings (x2) 90386-13007
Clutch pedal linear spring 90507-14030
Leather Manual Shift Knob 33504-20120-C0
Rubber manual shift knob 33504-20100-C0
Hvac bulb w/cover 90010-05152
Automatic Shifter Bushings (need 4) 90385-11003
Seat back pad 71551-35050
Seat bottom cushion 71511-35050
Ignition lock cylinder 6905735070 (non-transponder) 89703-35080 (transponder)
Transponder Key 89785-26020
Non transponder key 90999-00185
Key fob 89742-35050
ECT and Defrost Bulb 90010-01041
Hazard Bulb 84999-10860
Main Cluster Bulbs w/Green Cover 90010-06034
Rear Window Bulb 90010-01042
Instrument Cluster Plastic Screen 83852-3D200
Blower Motor 87103-35022
Blower motor resistor 87138-35050


Body
Rear pressure vent 62940-35020 (01-02 has hole for wire pass through)
Turn signal stalk w/fogs 84140-14120
Rear Hatch Struts Cold Weather 68907-35020 (R) 68908-35020 (L)
3 nozzle washer sprayer 85381-42070
Honda washer sprayer 76810-TK8-A01
Rear seat back clips 90467-06102
Rear headliner clips (need 6) 90467-09110
Lift gate weather strip 67881-35020
Trim panel retainers 67771-89110
Door panel/Upper rear trim retainer 67771-12050
Right Front Door Check 68610-35010
Left Front Door Check 68620-35010
Right Rear Door Check 68630-35030
Left Rear Door Check 68640-35010


Brakes/Axle
Rear Axle Brake Line Junction 90413-10263 $15
Brake booster check valve 44730-60060
Check valve grommet 90480-24015
Axle Boot kit (per axle) 04438-35061/04438-35062
Non ADD Axle Reboot Kit 04438-04021
Rear Axle Breather 90930-A3001 $11
Lexus front diff drain plug (14mm head) 90341-24016
Lexus front diff fill plug (14mm head) 90341-18060
Rear differential carrier bearings (x2) 90366-50007
Rear wheel bearing 90363-40020-77 or Nachi 6308-2NSE (96-00) / 90363-40068 or NSK 40BW06CG50 (01-02)
Rear axle retainer42423-20010 (2 per side)
Snap ring 90520-36045
Outer seal 90313-48001 (96-00) or 90313-54001 (01-02)
Inner seal 90310-50006
O Ring 90301-88077
Front diff drain 90430-24003
Front diff fill 12157-10010
Rear diff drain/fill 12157-10010 (x2)
Front Output Shaft Seal Left 90311-47027
Front Output Shaft Seal Right 90311-47013


Suspension
FRONT CAM ADJUSTERS
-plate 48452-35020
-bolt 90080-11283
-cam 48409-35050
L LBJ 43340-39465
R LBJ 43330-39585
Both LBJ 04005-02235 (no cotter pin/nut) Castle Nut 90171-A0005
LBJ Bolts (4 per side) 90080-10066 (96-00)(59 ft/lb), 90119-10933(01-02)(37 ft/lb)(Recommended for all applications after testing https://www.toyota-4runner.org/3754083-post35.html)
R lower control arm 48068-35081
L lower control arm 48069-35081
L/R Front Shock Top Plate 48609-35030
L Outer Tie Rod 45047-39215
R Outer Tie Rod 45046-39335
Jam Nut 90170-20003
Front end link bushings 90948-01003 (x4)
Rear end link bushings 48817-30020 (x4)
Front sway bar bushing 48815-35100 (x2)
Rear sway bar bushing 48815-10090 (x2)
Rear Upper Control Arm 48710-35040 (4wd) or 48710-35030 (2wd)
LC80 Rear Shocks
Centering washer 90948-02119? (1/side)
Bushing retaining washer (upper) 90948-02144 (2/side)
Tokico LC80 Rear Shock 48531-69417 (1/side)


Wheels
17x7.5 15mm offset/4.5” backspacing steel wheel 4261135330
17x7 TRD Pro wheel 4mm offset/4” backspacing PTR20-35110


Miscellaneous References
Subaru FMU H5010FC001/H5010FC000 (H5010FA001?)
Temp sensor H5010FC021
Temp sensor wiring harness H5010FC051
FMU wiring harness H5010FC040

Gentex 453 homelink/compass/temp gauge
8781835020 wire cover requires some trimming

Toyota lock wafers
Toyota TR47 Pinning Kit (A-30-108) – CLK SUPPLIES, LLC

Ford gas tank upper straps 43-4061
Rear-Mount Gas Tank and Components
38 gallon Ford tank Spectra F26E
18 gallon Ford tank Spectra F1G
Websites
2000 Factory Service Manual: Update your browser to use Google Drive, Docs, Sheets, Sites, Slides, and Forms - Google Drive Help
2000 Electrical Wiring Diagram: Dropbox - 2000 4Runner Electrical Wiring Diagram (EWD383U) - Printable - Simplify your life
1997 EWD: Toyota 1997 4Runner Electrical Wiring Diagram (EWD277U).pdf - Google Drive
1998 EWD: https://www.dropbox.com/sh/zu8ywkj4l...20EWD319U?dl=0
3rd Gen FSM (2002?): 4Runner FSM 1996-2002.pdf - Google Drive
Toyota Parts Diagram: https://parts.toyota.com/Toyota__4Runner.html
Clearing Tires At Any Height: https://www.coastaloffroad.com/clear...y-ride-height/ (explains suspension articulation regardless of ride height lift)

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

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

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.

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

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.

Attached Images

   

Great start. subscribed.

“Greige”

But seriously, awesome find. Looking forward to your posts!

Anxious to follow this along and see the progress as you catch up on the maintenance.
Don’t forget to include more pics!

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

Wow, no time being wasted here, lots done in short order, run Patrick run!!
Love Desert Dune on these Runners.

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

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..