About to become a new 4runner owner....but

[thegipper]

So here are the pictures of my jeep which the 4R will be replacing. It's a 95 ZJ 4.0 with 305k miles on the original engine. You will see what structurally compromising rust looks like. Even as bad as it is, it actually hasn't even failed yet but probably would in the next couple years. The 4R doesn't have rust anywhere even approaching this:

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[kurticus91]

Damn! Now that's some rust

 

[poleclimber63]

rust...

Rust is always the enemy in our Northern and Eastern climates. The East being the worst. My son bought a Mitsubishi Eclipse and I think it was slightly worse than your 4Runner. Make no mistake, if one has a choice, its far better to spend time looking for a vehicle with as least rust as possible, and I will even go so far as to say that, for long term ownership, its slightly more important than mechanical integrity. In your case you basically got this truck free! Rust remediation is a painful process (its always worse than you thought!) and time consuming. My son and I spent 2 weeks on his car, removing as may body panels (gave us the opportunities to fix the dens too!) and ground and wire wheeled eventhing we could access---- then doused it in POR15. I have no illusions that we've just slowed down the cancer but it should see him through a couple of years.
In your case, having access to talented welders is a godsend (maybe some body/bumper mods are in your future??!). Looking at your rust picks some of it maybe surface, some grinding and POR15 would definitely do the trick! I'd ask your buds to fab up some new crash plates--- they look like they're ready to fall off! Anyways this will be a great back woods beater! Good luck!

 

[thegipper]

As I stated before, the first thing I'll be doing is replacing every fluid on the vehicle, horn fluid included

I already have brake fluid and the coolant is all brand new since he replaced the radiator. Other than that, I got all new fluid and grease for all of the fittings (prop shaft ect).

I also needed a second set of stands (only had 2) and my brother said the factory jack was missing. I'm going to fab up a plate for the bottle jack so the surface area is much larger instead of the end of the tiny cylinder.

Exhaust will be next then the LBJs and suspension (thanks Kurt)

Now I just need the thing to be dropped off!

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[thegipper]

4R will be here Wednesday, talked with the shipping company today.

Here are some more pictures my brother took before it went on the truck. Like I said before, it's actually pretty clean...

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[kurticus91]

Looks good man! Cant wait to see the transformation of the truck. I got nervous because the Fedex tracking for the suspenion kept coming up blank but its finally showing up now. Says it will be delivered Wednesday :thumb3:

 

[thegipper]

Sweeet!

Oh my brother found the original jack too so he put it in it before it left for Wisconsin. I'll probably keep the bottle jack just to have.

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[poleclimber63]

4R will be here Wednesday, talked with the shipping company today.

Here are some more pictures my brother took before it went on the truck. Like I said before, it's actually pretty clean...


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Wow, rear bumper corners aren't perforated with rust... there's a ton of 4Runners around my, neck of the woods, with perforated rear bumpers...

 

[thegipper]

I just spoke with the driver and he said his truck is leaking coolant so it won't be delivered until tomorrow.....grrrrr

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[thegipper]

I received the donated springs, coil overs and KYB gas adjust struts from Kurt today. If Kurt reflects even a fraction of the generosity and help that is available on this forum, this is by far the best forum I have ever been on.

For him to do that for a complete stranger, really, is amazing. I really do appreciate it and I'll be sure to take before and after pictures once installed (hopefully this weekend).

Cheers man! I owe you a fine steak dinner and a some cold ones!

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[kurticus91]

Hell yeah man! I'm glad everything arrived in good condition. Hope it serves you well.

I'll be north of Chicago for Navy basic training this summer, maybe you can buy me a nice steak dinner then haha. Cheers!

 

[thegipper]

Sounds good!

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[poleclimber63]

I received the donated springs, coil overs and KYB gas adjust struts from Kurt today. If Kurt reflects even a fraction of the generosity and help that is available on this forum, this is by far the best forum I have ever been on.

For him to do that for a complete stranger, really, is amazing. I really do appreciate it and I'll be sure to take before and after pictures once installed (hopefully this weekend).

Cheers man! I owe you a fine steak dinner and a some cold ones!

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This is extremely generous and consistent with what many members do on this site. Most on this site are passionate about our 4runners and promoting the pastime of modding our trucks for recreational off roading etc. I'm a member of other forums, as I own other vehicles, and no other site comes close, except maybe Yotatech. Some forums are very inflexible making it hard to contribute freely with enthusiasm. This site is awesome!
By the way, you got a great deal!! I just pulled the trigger on OME906's and Rancho adjust shocks--- just the rear --$360...

 

[thegipper]

Here she is!

I'll be starting a build page probably this weekend. The work begins on saturday.

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[thegipper]

Tonight I inspected the frame rails through various access holes. Everything looks fine in there.

I also sprayed down various bolts and nuts that I will need to remove for the suspension. The sway bar bushings in the front are shot, looks like the brackets are not in the best condition either so I'll be replacing those too.

The engine......wow. It runs sooo smooth. I cannot believe how well it runs, it has almost zero valve train noise. I looked it over really well and no signs of leaks anywhere.

So far so good!

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[thegipper]

The skid plate that cover the gas tank is definitely not in the best condition. I think eventually I'll fab up a replacement at work. I'm thinking some 3mm Domex 100xf which is a 100ksi hardened steel plate. We use it for making parts for a certain military vehicle that will be replacing the Hummer

That material is extremely tough (hard) but also surprisingly flexible.

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[thegipper]

Ok guys just want to give a quick update. The rear suspension I got donated to me from Kurt has been installed. It raised the rear of truck by 1" which is pretty good because it wasn't really sagging that bad to begin with. It rides very nice now minus the clunking I'm still getting (made a new post to address that, I think its worn track bar bushings). I also broke both rear sway bar links so I got some new ones on the way, should be here tomorrow. The front sway bar bushings and brackets were also shot, so those have been replaced (another PITA).

I literally replaced every fluid in the vehicle, so that is all done. Hardest part about that was getting the rear differential fill/drain plug off. I also took the plastic fender flares off and repainted them.

I'll post pictures when I'm done tonight.

Next weekend will be new OEM LBJ's and the front suspension Kurt gave me. I also have some new sway bar links for the front.

The exhaust will be after that and eventually tires. Oh and instead of making a build thread, I think I'll just keep posting on this since I'm not "building" anything special. Just doing a semi restore for a "up north" vehicle. Hopefully others that are looking to the do the same can find this thread and get some helpful tips/ideas.

 

[thegipper]

More pictures

I also noticed some oily residue on this hose connection on the intake tube. Is this PCV related? It's not dripping or anything but I noticed it's wet. Thoughts?

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[thegipper]

New set of used tires for a $100 (money for new tires is now being used to fix stuff....of course). They are Cooper discovery with 40% tread left. They are a little noisy but will be fine for what I need them for.

I ground all of the rust away and sprayed rust stop on the cleaned up areas of the rocker panels. I then put two coats of bed liner on them.

Front coilovers, toyota LBJ'S and sway bar links all done this weekend. Also had to install a new outer tie rod that had play.

I still have a clunk/pop noise coming front the front end while pulling into my driceway. Only makes that noise when turning at low speeds and hitting a bump (the search continues).

I think I'll have the exhaust fixed next. I'm already at about $1800 including the shipping. Hopefully I can get the last of the issues resolved and keep the budget under 2500 which was what my goal was.

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[thegipper]

I forgot to add, I also did the rear diff breather mod. The old one was covered in rust so I figured it should be replaced any way.

I used 3/8" ID heater hose line instead of fuel line because it was WAY cheaper. The parts store wanted like $30 for 6' of fuel line instead of $7 bucks for heater hose. For the application, it should be fine. I ran the breather out by the gas cap like others did. It was insanely easy to do which was a nice change. Essentially everything I have had to work on so far has been a total PITA.