In my case, I removed the grease zert on a stock front 4wd driveshaft & it collapsed more than enough to use on the front with out modification. Still has an inch of compression left. The rear I slid the slip joint out 1.5" to mock up & although several people are running it that way I plan to have it re tubed to put the spline engagement back to original. All in all the conversion has been mostly bolt on, largely because of the advice of those that have done it before me.
The shifters & sealing them to the tunnel has been the biggest pain in the ass.
The cross member was easy.

Dropbox - 20200104_154212.jpg - Simplify your life

Nice work… These projects look somewhat hard to accomplish but you tend to make it look easy. My initial thought was just to sell and buy a 4WD truck haha.

The problem with that is you cannot buy a V8 2wd/4wd.
AWD is not what I needed.

Dropbox - 20200111_185140.jpg - Simplify your life

I guess maybe I take that for granted in my V6, but I don’t really do anything where I feel like “I wish I could have been in 2WD”, for that reason I would have been OK with the full time AWD system because you are not loosing capability for 4WD / off-road use.

Are you getting into a more sporty driving style off-road where you find 2WD characteristics to be more desirable?

Thanks for sharing, im planning on doing this to my 03 V8 2wd one of these days as well, to much sentimental value to let her go... any updates or issues with the swap or parts used?

On a V8 the front axle is always engaged, the transfer case is always engaged, the tires are always fighting for torque balance, the drive shaft is always spinning. IMHO that's all unnecessary drag and wear.
As a bonus I have no electronics for hi/lo to fail.

The V6 transfer case gives you more options so it's not as big of a deal on them.

Mines up and running, I'm very happy with it.
106k miles and just over $8000.00 total with a V8 cream puff and fresh 2wd/4wd

Was it worth all the work? What would you estimate the cost to do it all?

$800 Transmission, transfer case & ADD front axle
$300 for hubs/bearing assemblies & halfshafts
$50 4wd cross member with mount
$130 for both 4wd driveshafts
$100 misc, ATF, Gear oil,RTV etc

$1350 A good wrecking yard scrounger could do it cheaper

I splurged on the ADD harness & twin stick from RST so that's another $500
Not necessary but I wanted it

Definitively worth it to me. I have exactly what I wanted.

So your parts total was under $2K?! That's excellent. That's not much different than the used car price difference between 2WD and 4WD around my area. I'm sure that if you wanted someone to install it instead of DIY, it would be another $2k though!

My intended use is different than most. The primary function is to pull our little camper. We camp offroad & a good snow or shower could easily make it impossible for a 2wd to get back to pavement. The secondary consideration was being able to explore once we set up camp.

That’s literally my exact use case. I’m building out and fixing up the 4runner to be a daily (already is) that can tow and explore once we’ve set up camp somewhere. We’ve just been tent camping for now and exploring within the limits of our 2WD. “Run what you brung”

I doubt I’ll do the 4WD conversion anytime soon as our young kids make the truly off grid stuff less realistic for us, but it’s super cool to see how much work, and yet how little, this takes at the same time.

“It can’t be done!” Became, “well you could, but it’d be too expensive.” People did it anyway. Now it’s like, “here’s the condensed list of parts. If you can do it yourself, it’s like a couple grand and sweat equity.” Rock on dude.

Took it for a ride just now, drives just like it did before unless I pull the two new levers
Everything works as it should.

Cool project and nice job! A lot of people forget about the research involved to make a project like this go as planned. Just because someone (usually a fabrication shop) has done it before doesn't make it any less impressive imho. Glad it went well for you!