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Old 01-08-2018, 01:17 AM #1
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1995 4runner DD/adventure rig "Killbox"

Hey all, finally got around to getting some posts built up on here for privileges, so thus starts the 2nd gen build thread for Killbox. Side note - why is the 2nd gen forum these days full of crickets? Did everyone buy new runners and forget the nostalgia? Anyways:
1995 4runner DD/adventure rig "Killbox"-img_4443-jpg
Specs:
1995 sr5 4runner 4x4
Sierra Beige Metallic, tan cloth interior
3.0 3vze, 5speed r150 transmission
4.56 factory gears, OEM Toyota tow package

I lucked into this 4runner that had been sitting in a buddy's yard for six years. He had picked it up due to its immaculate nature, knowing that someday he would build it into a super clean daily. I convinced him to pawn it off on me for $2000 with a locked up 3.0 and plenty of filth. I wanted this build to be simple, fairly cheap, and to extend the lifespan of the motor and chassis with tasteful modifications that would give me more peace of mind on extended trips and off-road.

Modifications/upgrades:
AC delete
Auto hub delete (Aisin manual hubs)
Cat delete (lc engineering)
Chrome delete
EGR delete (lc engineering)
Auto antenna delete (broken anyways)

4 crawler offroad 1.5" BJ spacer/rear coil spacer, sway bar drop, rear proportioning valve spacer, 1" diff drop
Moog stock size rear coils
KYB red +2 F shocks
KYB red R shocks
Trailgear weldable shock mounts
F/R sway bar end links
OEM cat back exhaust (rusted out)
New front rotors/pads/calipers
New CV axles L/R
New FR wheel bearing
New tie rod ends
New BJ U/L
Marlin Crawler short shift kit
Yakima rack system
BFG 33x10.5x15 on steelies
Ebay seat covers with Molle attachments
Wrap crossover manifold with heat wrap
Vision X 9004 bulbs
Vision X 4.5" LED fog lamps/amazon light bar wired to OEM Toyota fog switch
Red LED map lights, LED cargo lamp, LED reverse bulbs
Synthetic gear lube F/R diffs, Tcase, Trans
Diff breathers
Replaced rear wiper blade
Bosch Icon wipers

Future plans:
4x4 labs rear bumper (with no attachments)
ARB bull bar front bumper
Rocky road super sliders
Safari snorkel with dust collector
x5 31x10.5x15 Toyo MT's on SR5 aluminum rims
Yukon grizzly locker (rear)
Total chaos caddy idler arm

Maintenance:
All 3 remaining wheel bearings
OEM u-joints X3
Pinion kit for locker install

Camping:
Leaning towards the Tepui Autana Ruggedized Sky model in expedition orange
Tepui luxury mattress, double boot bag, Autana weather hood

I like Tepui because there are a few dealers up here in Alaska for them, and can possibly purchase through REI and utilize the membership bonuses + free shipping

I have the Yakima round bar system in place now on the OEM tracks, but with the tent it would be pretty high off the top of the truck, so looking at Off-road unlimited defender factory roof mounts with a custom aluminum frame the dimensions of the tent mounts to keep things low, also maybe tied in with the existing Yakima racks above the doors for some sort of a basket/rack to be able to utilize that storage space as well.

Motor build:
Started out by ripping out the frozen block, dropping transmission, and emptying all fluids out of the cases, which all looked fairly good besides the engine oil which was the consistency of molasses. After guts were out rolled it outside for a proper and thorough pressure wash, which was fantastic for both the truck and my OCD.

Block had grenaded so it was trash, found a donor long block from a 90 runner and scavenged some Yakima track racks off it and the motor. Tore that motor down to the block, cleaned, cleaned and cleaned. The PO had used RTV on everything, and it had infiltrated all the internals. Wonder it ran. They even used it on the HG.

Sent off original heads for resurfacing, came back clean and flat, as well as resurfacing of crankshaft in a few spots. Didn't bore out the block as I wanted to keep things stock, just done right. Fresh rings, bearings, seals throughout. New head studs, high-quality HG, OEM water pump/oil pump/timing belt/plugs/wires/distributor/Knock sensor & pigtail etc. Basically everything new except the heavy bones. Wrapped crossover exhaust with heatwrap, and deleted the oil cooler (Alaska) in favor for a dual filter setup as seen in pictures to follow. I know alot of people frown on the 3.0 build, but the truck came with basically everything I needed to rebuild with OEM parts (previous Toyota parts tech & graduated 3.0 junkie), minus a hydraulic tensioner and a few other small bits.

While that was happening, we installed the spacer lift, new front CVs, tie rods, BJ's x4, front shocks, and removed the ADD and swapped on Aisin hubs, also loosening the torsions as the PO had them cranked so stiff you couldn't cycle the suspension.

The rear treatment consisted of ditching old springs, shocks, shock mounts in favor of new OEM height springs with spacer-lift, and relocated shock mounts to run stock height shocks.

Motor went back in smoothly, started up nicely but ended up fighting the dreaded 52 code (KS), as well as code 14 and 21 (ignition & o2). Relocated knock sensor to the side of the intake manifold where the egr had been deleted from, replaced ignition control module with new/used unit, fresh Denso 02 sensor and a new fuel filter for good measure fixed all my code issues. Still wasn't right, dug around and found the PCV valve we had replaced and had never hooked up again, made a huge difference, but still not there. Advanced timing to between 11-13, woke the motor up! All codes cleared and running great, she's due for her 1000 mile oil change in about 800 miles. Running Mobil 1 full synthetic with OEM toyota filter(s).

Cheers
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Old 01-08-2018, 01:25 AM #2
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1995 4runner DD/adventure rig "Killbox"-img_3951-jpg

1995 4runner DD/adventure rig "Killbox"-img_3952-jpg

1995 4runner DD/adventure rig "Killbox"-img_3966-jpg

1995 4runner DD/adventure rig "Killbox"-img_3971-jpg

1995 4runner DD/adventure rig "Killbox"-img_4053-jpg
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Old 01-08-2018, 01:33 AM #3
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1995 4runner DD/adventure rig "Killbox"-fullsizeoutput_118e-jpg

1995 4runner DD/adventure rig "Killbox"-fullsizeoutput_118f-jpg

1995 4runner DD/adventure rig "Killbox"-img_4091-jpg

1995 4runner DD/adventure rig "Killbox"-img_4251-jpg

1995 4runner DD/adventure rig "Killbox"-img_0786-jpg

1995 4runner DD/adventure rig "Killbox"-img_0789-jpg
Attached Images
1995 4runner DD/adventure rig "Killbox"-img_4105-jpg  1995 4runner DD/adventure rig "Killbox"-img_4119-jpg 
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Old 01-08-2018, 01:42 AM #4
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1995 4runner DD/adventure rig "Killbox"-img_0775-jpg

1995 4runner DD/adventure rig "Killbox"-img_4264-jpg

1995 4runner DD/adventure rig "Killbox"-img_0850-jpg

1995 4runner DD/adventure rig "Killbox"-img_4271-jpg

1995 4runner DD/adventure rig "Killbox"-img_4281-jpg
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Old 01-08-2018, 01:47 AM #5
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1995 4runner DD/adventure rig "Killbox"-img_4417-jpg

1995 4runner DD/adventure rig "Killbox"-img_4418-jpg

1995 4runner DD/adventure rig "Killbox"-img_4424-jpg

1995 4runner DD/adventure rig "Killbox"-img_4426-jpg

1995 4runner DD/adventure rig "Killbox"-img_4428-jpg

1995 4runner DD/adventure rig "Killbox"-img_4429-jpg
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Old 01-08-2018, 11:52 AM #6
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Nice job! There are still a few of us that love the 2nd Gens

Looks like you decided to eliminate the oil cooler and add a second filter? Or you found it that way? I've thought about that a few times. I resealed mine, and it was clean (on the my '95... the '92 was full of crud) so I left it in use when I went through my engine.

Nice build, tho! Do you have a link or brand of your lights?
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1995 3.0 Manual - Second Project - Sold-
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Old 01-08-2018, 12:58 PM #7
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i like the color, and the runner in general. looks nice, and should serve you well.

i also like the stock alloy wheels. a solid look for the 1st and 2nd gens.
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1987 4runner sr5, 22re, 5-speed
1988 4runner sr5, 3.0, auto (parts rig)
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Old 01-08-2018, 04:30 PM #8
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Its cause were all broke haha. But seriously your build is beautiful and I hope my runner looks that nice some day. Good Job and I hope to see more upgrades in the future.
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Old 01-08-2018, 07:01 PM #9
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Quote:
Originally Posted by HanginInUtah View Post
Nice job! There are still a few of us that love the 2nd Gens

Looks like you decided to eliminate the oil cooler and add a second filter? Or you found it that way? I've thought about that a few times. I resealed mine, and it was clean (on the my '95... the '92 was full of crud) so I left it in use when I went through my engine.

Nice build, tho! Do you have a link or brand of your lights?
https://www.amazon.com/gp/product/B0...?ie=UTF8&psc=1 (switch)

https://www.amazon.com/gp/product/B0...?ie=UTF8&psc=1 (light bar)

www.superbrightleds.com (interior, reverse)

https://www.visionxusa.com/shop/4-5-light-cannon/ (fogs, used)

not sure where I found the light bulbs. I think this grill took an H4 bulb, and I possibly sourced them off of Ebay early on in the game. There is a local shop that quoted me 300 bucks to install HID's with a lifetime warranty, I might take them up on it later down the road, pretty happy with the vision x h4s, and with the fog lights have zero issues on empty roads. The light bar is just for show basically, but does light up the road closer to the truck while the fogs shoot farther on down the road.

Made the decision to eliminate the oil cooler on the fly during the build - tapped and threaded a plug into the water pump, installed an oil filter bung from the old block, and capped a small hole in the side of the block above the cooler and behind the motor mount when it was all torn down. Between oil cooling and oil filtration I chose extra filtration, there are only a few hot days a year up here in Alaska so the cooler wasn't critical, and I wanted to keep as much crud out of the oil as possible! As well as getting rid of extra lines under the hood for access/decreased potential failures.

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Old 01-08-2018, 07:04 PM #10
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Quote:
Originally Posted by wallytoo View Post
i like the color, and the runner in general. looks nice, and should serve you well.

i also like the stock alloy wheels. a solid look for the 1st and 2nd gens.
Thanks! Yeah the color/paint ended up being really nice, minus a few rust spots seen in pictures on the rear fenders. Once summer comes around and things dry out I am planning on hitting those spots, and all the other little rust spots with ospho, then repainting with some factory matched touch-up paint.

The stock wheels are the way to go for 31's I feel. Running with stock specs on BS should extend the longevity of the wear and tear of both the front end and all the wheel bearings. I bit off too much with the 33's, runs good but a bit too big for my tastes.
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Old 01-08-2018, 07:05 PM #11
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Quote:
Originally Posted by 1990silverbullet View Post
Its cause were all broke haha. But seriously your build is beautiful and I hope my runner looks that nice some day. Good Job and I hope to see more upgrades in the future.
Thanks! Appreciate the kind words. Good luck with your build!
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Old 01-09-2018, 01:42 AM #12
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nice

Quote:
Originally Posted by O.B.A.K View Post
Thanks! Appreciate the kind words. Good luck with your build!
Nice job! I'm finishing my sons now with the final touch an elocker. You really have all of the right stuff.
I also rebuilt my 3.0 and found the KS issue to be in the harness and built a small replacement harness and kept the functionality if the sensor. The wiring seems to take a beating from the heat in the engine compartment. Once again really nice!
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Old 01-09-2018, 12:43 PM #13
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Great looking 2nd Gen, We are still around just not as common as they used to be.
I probably see 6-10 3rd and 4th gens for every 1st or 2nd gen on the road.
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Old 01-11-2018, 12:20 AM #14
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Esquire

Got out while the light was good today and got some glamour shots. Forgot to shoot some of the engine bay, wanted to show off the hardline delete and knock sensor relocate for anyone who would be interested. I'll try to get them up at some point this week. Making it a goal of 2018 to get this rig off the pavement at least once a week, even if it's a micro adventure close to home. Cheers -

1995 4runner DD/adventure rig "Killbox"-img_4471-jpg

1995 4runner DD/adventure rig "Killbox"-fullsizeoutput_11a1-jpg

1995 4runner DD/adventure rig "Killbox"-img_4473-jpg

1995 4runner DD/adventure rig "Killbox"-img_4475-jpg

1995 4runner DD/adventure rig "Killbox"-img_4476-jpg

1995 4runner DD/adventure rig "Killbox"-fullsizeoutput_11a8-jpg

1995 4runner DD/adventure rig "Killbox"-img_3522-jpg

1995 4runner DD/adventure rig "Killbox"-img_4469-jpg
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Old 01-11-2018, 12:24 AM #15
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Glamour cont.

1995 4runner DD/adventure rig "Killbox"-img_3471-jpg

1995 4runner DD/adventure rig "Killbox"-img_3472-jpg

1995 4runner DD/adventure rig "Killbox"-img_3474-jpg

1995 4runner DD/adventure rig "Killbox"-img_3511-jpg

1995 4runner DD/adventure rig "Killbox"-img_3498-jpg
Attached Images
1995 4runner DD/adventure rig "Killbox"-img_3517-jpg  1995 4runner DD/adventure rig "Killbox"-img_3521-jpg 

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