@Inv4drZm Now for the next question Mason, will our oem pumps be able to handle the volume?
According to James' measurements, the LC stroke is a hair shorter, but the larger rack has got to hold a pint or two more fluid.

Wow, that LC200 rack is so much more beefier than the rinky dink 4runner rack. I don't know what Toyota was thinking putting these inferior steering racks in, just causing us owners to put more time and money to 'beef' things up!!

It should be fine, I haven't heard Marlin or anyone mention that.

Would be nice to upgrade the fluid capacity though to be on the safe side. James on the FJC forums did with an aftermarket reservoir.

Or if you had a ton of money burning a hole in your pocket just buy the JD Fab steering pump upgrade kit.

Reservoir sounds doable cost wise. Still want to get the clevis kit and the double shear kit, but need to sell some of the parts accumulating around the house.
After 20 years, I'm officially unemployed to start the New Year, so I'll have plenty of time, just not the full budget I was hoping for.

Well I just dove in the deep end.
Rear end swap: new/used one has 4:56 Nitro gears/Nitro axles-ARB locker. It also has legitimate bumps stop pads, tabs welded on for an Anti-Rock and the lower shock mounts will accommodate the welded rod ends for the bypasses.
FJ tank is 19 gallons and shorter to accommodate more down travel.
Out with the old:

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Decided to pull the T-case too. Got done right before dark.
Supposed to rain tomorrow so I wanted to get ahead of that.
Edit: @scrappyted83 just mocked up your shifter 180 flip on the manual, great idea!

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Got the t-case in and waiting on drive shafts now. Like to thank everyone who has done this mod and posted all the pics and info: @aha2988 @ryanking61 @xtremewlr @mysticz . If I missed anyone sorry about that.
I pretty much copied everyone else right down to the shifter boot from Autozone. Why change something that works perfectly. I put the ground for the dash indicator lights inside the cab to resist corrosion, and I didn't pass the A/C duct back to the rear as I plan on pulling my rear seating anyway. I also added a Marine cig outlet to the console to replace the one that gets taken out in the coin slot.

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So I learned last year from a 4th gen guy out in San Diego, that the 19 gal FJ fuel tank will bolt right up with a few mods to the straps and plumbing. He then installed an aftermarket FJ fuel skid and called it a day. I am going to see if I can modify the OEM 4th gen skid and make it work.
Now you might say what is the point? Thats LESS fuel capacity. A valid concern for those that DD or have Overlanding Wanderlust.

I however am in pursuit of more travel, and not the overlanding type. Here is a picture of the two to explain what I'm after. The OEM 4th gen tank is on top which is pretty much maxed out on down travel with the upper link and spring in contact with the tank, and the FJ tank on the bottom allows a few more inches of clearance. Which I believe will equate to several more inches of down travel at the wheels, once I get my pinion angle sorted out and LT shocks in there. If you use the frame mount for the upper link as a reference, you can see how much shorter the FJ tank is.

The lower links are the restricting factor in the pic on the bottom, so with the pinion angle raised several degrees, this will allow even more droop and then I'll strap it to a safe limit. But, the FJ tank will not be in play as much as the OEM 4th gen.

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Nice work on the tcase! Have you had a chance to try it out yet?

Great information about the FJ fuel tank. Right now, the 4runner is still my daily but that will change soon enough. Since I run the spare out back instead of underneath now, there is a ton of room for a 2nd fuel tank to get some of that capacity back and still have room for suspension travel. Something to think about if you need that extra capacity at some point.

So with the 4th gen tank removed, I put the FJ tank in and shuffled things around. The fuel pump housing for the FJ tank pretty much sits in the same position as the 4th gen tank. So I will swap out the main feed and return lines going to the engine from the 4th gen, and the electrical connection will not need altering.

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The filler neck will have to be lengthened, and the evap vent hose might be able to be stretched into place. But I THINK that is it for the plumbing and electrical.

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I wish I could figure out how to insert pics and text like @y=mx+b , so as not make so many posts, but that's for another day lol.

Now for the retaining straps. I am blessed with a relatively rust free undercarriage so this wasn't too bad of a job.
The forward strap fits in the same place, I just had to shorten and bend it to fit the smaller profile of the FJ tank. I decided to bolt it into the hole where the skid bolts in, so it will share this mounting point with the skid.

The rear strap was a bit of a brain tease at first, as it does not line up with any of the mounting points. So I got the band saw and welder out (don't look to close at those welds lol), fabbed up a little bracket, then drilled and tapped it for the outside frame mount. Then I put a sleeve and bolt in for the inboard mounting point and I think it will be pretty secure.

So now I can bring it back down, put the FJ fuel pump housing in, paint everything, and start work on modifying the 4th gen skid to fit.

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No I haven't tried it out yet. I just dropped the drive shafts off today and it will be awhile before the front diff matches the 4:56 gear in the rear end anyway.

I plan on running the Currie Anti Rock sway bar back there, so I don't know about adding an aux tank. But your right, there is a shit ton of room back there. I may try to fab up a hitch carrier for my spare one day, but right now it takes up most of the cargo space.

I plan to take the back seats out and may have to bust through the rear fender well to get these 14" triple bypasses to work back there. I'm in over my head for sure lol.

Did you happen to compare or measure the ground clearance difference between the two fuel tanks?

The front half of the FJ tank is angle upward so I think that's probably the extent, maybe 1.5" extra clearance?

Damn. I’ve been off the forum for a while. Taking this beast to the next level, I love it!


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